A few months ago, we introduced our Lattice Design Suite (LDS), an Add-In for Fusion 360 designed to streamline the process of lattice structure creation. Today, we’re very pleased to share that its core functionalities are now implemented! This milestone calls for a deeper look into the features that make LDS unique and the guiding principles that shaped its development.
The Problem with Existing Software
Current software for designing lattice structures falls short in several ways, particularly for creating efficient ASLM-manufacturable lattices. Most available tools were developed with general 3D printing in mind and are therefore quite basic in their latticing capabilities. For example, many only allow users to generate regular lattices that are then intersected with volumes, often resulting in disconnected struts at the boundaries. These lattices may be attached to a printed skin, but such approaches can lead to structural or functional weaknesses, especially when using ASLM.
For software that does support conformal latticing, the process is often overly automated. One-click solutions prioritise convenience but lack flexibility, are difficult to locally modify, and are unsuitable for ASLM manufacturing (short beams, too skewed angles…), as manufacturing constraints need to be taken into account when designing.
This automation also reduces the role of engineers when designing. Many tools fail to provide the flexibility needed for creating custom, complex lattice geometries: Instead of empowering engineers, they impose limitations, forcing workarounds and leaving little room for human expertise to influence the final design.
Our Approach
We wanted this solution to integrate seamlessly into traditional CAD software, enabling users to easily modify lattices using existing tools and incorporate them into larger assemblies. Hence, our approach is very different from current lattice design, merging the advantages of traditional CAD workflows with the specific requirements of creating lattice structures.
In contrast to automated lattice generators that favour convenience over control, our Add-In enables engineers to have an active role in shaping their designs, harnessing their expertise and creativity.
Our Workflow
At the core of our philosophy is the belief that traditional CAD workflows are not only relevant but also well-suited for smart lattice creation. Instead of starting with meshed volumes, we focus on meshing 2D sketches—a long-standing cornerstone of CAD design. This approach makes lattice structures more intuitive to create and easier to modify, while avoiding the complexities and limitations often associated with algorithmic volume meshing.
With our LDS Add-In, the process begins just like any traditional CAD design: with a simple 2D sketch. This sketch is transformed into a meshed sketch, which can then become a volume using familiar operations like extrude, revolve, or loft to create volumetric, conformal lattices. These lattices can be easily modified and combined together, offering flexibility and control throughout the design process.
By mirroring the traditional CAD workflow, our approach ensures that engineers can seamlessly apply their existing knowledge and expertise. This allows every lattice structure to be purpose-built, tailored to its specific application, and fully aligned with the designer’s intent.
 |  |
 |  |
 |  |
Even with thoughtful design, it may sometimes be necessary to modify beams, add connections, or identify problematic geometries during the modeling process. To address these needs, we’ve implemented local modification functions directly into our Add-In.
Finally, since lattices can be computationally intensive to model, we have worked hard to reduce machine time by incorporating efficient workarounds, ensuring that creating lattices is not only powerful but also practical. For example, many lattice structures can consist of thousands of elements. Most CAD software are not built to accommodate these amount of elements. We use an intermediate mesh representation to quickly inspect, iterate and develop lattice structures, and at a final step we convert everything to a BRep definition for simulation.
If you’d like to learn more, don’t hesitate to reach out!