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Topology Optimisation
2015

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Want to know more about design for 3D
printing, including Topology Optimisation?
Contact us at: info@fransisco.nl

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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

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Fransiscó
Since 2009 | Design support for clients | 3D printed Adventure Motorcycle

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Why 3D printing?
Local production | Complex parts | Customer specific

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Industrial revolution
Since 1800 | Begin mechanisation | Mass manufacturing | Limited design
variables

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Expensive tooling
Large investments required | Large production numbers | No customisation

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Production lines
Limited flexibility | Large investments required | Large production numbers

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3D printing = goodbye big factories

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But how to design for 3D printing?

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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.”

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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

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Relevance for 3D printing
Organic complex shapes | Based upon bone growth | Lightweight & Stiff

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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

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Design goals
Minimum weight | Certain Eigen-frequency | Maximize stiffness @ weight %

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Swingarm redesign
Optimised for 3D printing in titanium

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Design Space
Non Design Space
Design space
What can be optimised & what not

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• Brake
• Accelerate
• Cornering
• Obstacles
Load cases & functionality
What’s the use case of the component | This is the hard part

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Results
Optimised for maximum stiffness | Raw output | Resembles a bone | Large
voids

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2015 Additive World Award Winner
Detailing
Organic shapes | Integrated functionality

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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

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Large variations
700 different solutions to a ‘simple’ well defined problem

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Person behind the buttons has
huge influence

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Market players

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Altair
Established name | Powerful engine | 3D printing mindset
Concept Engineer Simulation Engineer
For inspirational
optimisation studies
Industry standard
Increased functionality,
requires a specialist

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Autodesk
Focused on 3D printing | Generative Design | Lattice structures
CAD integrated Lattice structures

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Lattice Structures
Support for hollow structures | Dedicated analysis required

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Dassault Systems
FE-Design | Abaqus – NASTRAN - ANSYS plugin

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CAESS
Requires PTC Creo | Plugin | Powerful cleanup tool | Lattice structures

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Frustum Cloudmesh
Remote computing power | Lower upfront investment | Beta test Q4 2015

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nTopology Element
Lattice structures | Beta testing now running

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Future Developments
Incorporate 3D print rules, process & material | Integrate 3D CAD | Auto
smoothing

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• Use it for inspiration
• Shorten development time
• Engineer still needed
Takeaways:

36.
info@fransisco.nl