Optimization of 3D printed porous materials accounting for manufacturing defects



Open-cell materials are well-known for their low price, low weight, and broadband acoustic behavior. They form one of the most used class of acoustic treatments but suffer from a lack of versatility when made by conventional manufacturing processes. Recent advances in additive manufacturing allow to produce porous materials having a controlled microstructure. In this way, the design of treatments including porous materials is not limited to a catalog of existing media. The macroscopic behavior is governed by the micro-geometry of the porous medium, which can be estimated by numerical models. Then, acoustic treatments can be optimized numerically using predicting models and minimization algorithms. However, additive manufacturing induces defects often too complex to be accounted for numerically. In this presentation, a method allowing to obtain the parametric model of the intrinsic behavior of a 3D-printed porous material is presented. The corrected model is used in the optimization of several porous treatments; namely, graded porous materials, folded porous materials and metaporous surfaces. These treatments are versatile and display remarkable properties. They provide quasi-perfect absorption at several frequencies that can be out of reach of standard porous treatments in normal or oblique incidence. Experimental validations confirm the relevance of the proposed design processes.