Topology Optimisation for 3D Printing
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3D printing (additive manufacturing) will have a huge impact on future society. The vision is that you no longer need big factories, expensive tooling and long complicated production facilities to produce high end product. Manufacturing is brought back locally, with labor and environmental benefits as a result. All nice and well, but how do you optimally design for 3D printing? One important tool is Topology Optimisation, a software tool that helps in creating complex, lightweight and stiff optimised components.
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Topology Optimisation for 3D Printing
- 2. Want to know more about design for 3D printing, including Topology Optimisation? Contact us at: info@fransisco.nl
- 3. Education: 1999 – 2003: Bachelor Automotive Engineering 2003 – 2007: Master Mechanical Engineering Work experience: 2007 – 2008: Inalfa Roofsystems Venray 2009 – 2011: Stork Foodsystems 2011 – 2014: SKF 2009 – now: Fransiscó in/GilbertPeters Gilbert Peters GilbertPetersNL @Fisco_GP
- 4. Fransiscó Since 2009 | Design support for clients | 3D printed Adventure Motorcycle
- 5. Why 3D printing? Local production | Complex parts | Customer specific
- 6. Industrial revolution Since 1800 | Begin mechanisation | Mass manufacturing | Limited design variables
- 7. Expensive tooling Large investments required | Large production numbers | No customisation
- 8. Production lines Limited flexibility | Large investments required | Large production numbers
- 9. 3D printing = goodbye big factories
- 10. But how to design for 3D printing?
- 11. Topology optimisation “is a mathematical approach that optimises material layout within a given design space, for a given set of loads and boundary conditions such that the resulting layout meets a prescribed set of performance targets.”
- 12. Size Optimisation Topology Optimisation Shape Optimisation e.g. Thickness of a beam or X-section e.g. Position of a hole Complete shape, including holes F F F
- 13. Relevance for 3D printing Organic complex shapes | Based upon bone growth | Lightweight & Stiff
- 14. Topology Optimisation design flow Traditional design flow Design (CAD) CAE Virtual test Build Test Redesign Redesign Design Optimisation Design (CAD) CAE Virtual test Build Test Optimisation Resource savings
- 15. Working principle Define contribution of elements | Test against optimisation criteria F
- 16. Design goals Minimum weight | Certain Eigen-frequency | Maximize stiffness @ weight %
- 17. Swingarm redesign Optimised for 3D printing in titanium
- 18. Design Space Non Design Space Design space What can be optimised & what not
- 19. • Brake • Accelerate • Cornering • Obstacles Load cases & functionality What’s the use case of the component | This is the hard part
- 20. Results Optimised for maximum stiffness | Raw output | Resembles a bone | Large voids
- 21. 2015 Additive World Award Winner Detailing Organic shapes | Integrated functionality
- 22. Benchmark 1 part 16 parts Motorcycle swingarm redesign Less parts | Customised | Less machining | Brake system integration
- 23. GE Engine Bracket Design Challenge | +/- 700 entries | Simple load case & dimensions
- 24. Large variations 700 different solutions to a ‘simple’ well defined problem
- 25. Person behind the buttons has huge influence
- 26. Market players
- 27. Altair Established name | Powerful engine | 3D printing mindset Concept Engineer Simulation Engineer For inspirational optimisation studies Industry standard Increased functionality, requires a specialist
- 28. Autodesk Focused on 3D printing | Generative Design | Lattice structures CAD integrated Lattice structures
- 29. Lattice Structures Support for hollow structures | Dedicated analysis required
- 30. Dassault Systems FE-Design | Abaqus – NASTRAN - ANSYS plugin
- 31. CAESS Requires PTC Creo | Plugin | Powerful cleanup tool | Lattice structures
- 32. Frustum Cloudmesh Remote computing power | Lower upfront investment | Beta test Q4 2015
- 33. nTopology Element Lattice structures | Beta testing now running
- 34. Future Developments Incorporate 3D print rules, process & material | Integrate 3D CAD | Auto smoothing
- 35. • Use it for inspiration • Shorten development time • Engineer still needed Takeaways:
Notes de l'éditeur
- Trained as automotive engineer, always at the forefront of innovation. Weather it is electric vehicles, autonomous driving or 3D printing.
- ...while driving a Harley Davidson Electra Glide across the Nevada desert on the Extraterrestrial Highway. Almost running out of gas in the late evening fueled a brainstorm about a solar charged electric adventure motorcycles. Days later a testdrive on an electric motorcycle was arranged.....while not impressed by that product, the potential was was clearly there.
- Electric Motorcycles Silent high performance riding = addictive Achieving CO2 + emission targets with conventional tech => expensive Polluting becomes socially unaccepted Modern + high-tech image Applicable to local manufacturing
- Industrialization marked a shift to powered, special-purpose machinery, factories and mass production. The iron and textile industries, along with the development of the steam engine, played central roles in the Industrial Revolution, which also saw improved systems of transportation, communication and banking.
- Design objectives: Lightweight Function and part integration Topology optimized design