L'optimisation topologique est une méthode mathématique complémentaire avec l’analyse de Structures par Eléments Finis, qui permet l’automatisation de la distribution optimale de la matière dans un espace de conception donné, tout en prenant en compte certaines contraintes de chargement, d’encombrement, de fabrication, etc. Dès les années '90 et à travers de multiples thèses de doctorat, l’Université de Liège a été l’un des précurseurs au niveau mondial dans l’implémentation logicielle de cette méthode qui s’applique à de nombreux domaines. Toutefois, un de ceux-ci se distingue particulièrement à l’heure actuelle. Il s’agit de la fabrication additive. En effet, celle-ci devient importante pour l’industrie au sens large, parce que l’optimisation topologique y offre de nouvelles perspectives pour rencontrer les spécifications structurales et multidisciplinaires de beaucoup d’applications, avec des performances supérieures et des bilans de masse inférieurs aux structures fabriquées par les procédés traditionnels. C’est pourquoi Siemens propose actuellement une chaîne logicielle de simulation intégrée, combinant la conception en environnement CAO, l’optimisation topologique par Eléments Finis, la simulation du procédé de fabrication, jusqu’au dialogue avec l’impression 3D proprement dite.

1. Vendredi 26 février 2021
Optimisation topologique et simulation
intégrée pour la fabrication additive
Pierre Duysinx Professeur Ordinaire (A&M Department,
Faculté des Sciences Appliquées, Ingénierie des
Véhicules Terrestres Aérospatiale et Mécanique,
ULiège), Didier Granville Directeur Stratégie R&T
(Siemens Digital Industries Software Samtech)

2. LIEGE CREATIVE, en partenariat avec :

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Pierre DUYSINX
University of Liège
Faculty of Applied Sciences
Aerospace and Mechanical Department
Topology Optimization
and Additive Manufacturing: What’s next?
Pierre Duysinx, Eduardo Fernández Sánchez*, Simon Bauduin*, Pablo Alarcón*, Ioanna Koutla*,
Maxime Collet*,+, Frédéric Duboeuf$, Etienne Lemaire$, Didier Granville$.
1
* University of Liège, Aerospace and Mechanical Engineering Department, Liège, Belgium.
$ Samtech – Siemens, Liège, Belgium.
+ SAFRAN AERO BOOSTER, Liège, Belgium
Liège Créative Février 2021

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Pierre DUYSINX
• Historical perspective
– A material distribution problem.
– A creative tool
• Extending topology optimization to other physics
– From structures to thermal, fluids and complex systems
– Topology optimization and additive manufacturing
• What’s next?
– Energy conversion challenges: electromagnetics, heating and cooling, fuel cells…
• Conclusion and Perspectives
Liège Créative 2
Table of Content
Février 2021

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Pierre DUYSINX Liège Créative 3
AN HISTORICAL PERSPECTIVE
Février 2021

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Pierre DUYSINX Liège Créative 4
Historical perspective: Why Topology Optimization?
Deadlock in design based on CAD using parametric description of geometry
Zhang et al. 1993
Modification of
geometry model
parameter
A better topological layout
Modification of the
component morphology
(Duysinx, 1996)
Février 2021

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Pierre DUYSINX Liège Créative 5
Historical perspective: an intuitive approach
Variables !" , 0 ≤ &' ≤ 1
Max. Performance
s.t. Design
Constraints
• Concept of optimal material distribution
(Bendsoe et Kikuchi, 1988)
• Implicit definition of the geometry è
bitmap representation
• Functional definition
of the design: max
service function for
given resources and
design specifications
• We are clearly in preliminary design approach
Février 2021

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Pierre DUYSINX Liège Créative 6
Historical perspective: an intuitive approach
Variables !" , 0 ≤ &' ≤ 1
Max. Performance
s.t. Design
Constraints
Intuition-based design
?
Février 2021

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Pierre DUYSINX Liège Créative 7
Historical perspective: an intuitive approach
Variables !" , 0 ≤ &' ≤ 1
Max. Performance
s.t. Design
Constraints
Topology optimization: a new design tool that
offers innovative design ideas! New design!
Février 2021

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Pierre DUYSINX Liège Créative 8
Application: Aircraft engine pylon
• Minimization of compliance
14 load cases
– Static linear FE with SAMCEF
– SAMCEF TOPOL
– CONLIN solver
– Continuous interpolation law. Courtesy of Samtech and Airbus Industries
Février 2021

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Pierre DUYSINX
• Topology to minimize gear misalignment (inefficiency)
Liège Créative 9
Application: Planetary Gear of an Automatic Transmission
• Blue = void
• Red = material 210 GPa
Février 2021

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Pierre DUYSINX
• Comparison of single and multimaterial designs
Liège Créative 10
Application: Planetary Gear of an Automatic Transmission
Février 2021

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Pierre DUYSINX Liège Créative 11
EXTENDING TOPOLOGY
OPTIMIZATION TO OTHER
PHYSICS
Février 2021

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Pierre DUYSINX Liège Créative 12
Extending the scope of topology optimization
Structural optimization
Composite structures
Dynamic loading using MBS
Stress constraints
and fatigue
Thermo-Fluids
Buckling constraints
Multimaterial
MEMS (electromechanical systems)
TO & Additive Manufacturing
Electromagnetics
CONLIN (C. Fleury)
Février 2021

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Pierre DUYSINX Liège Créative 13
Topology Optimization & Additive Manufacturing
Courtesy of SAMTECH S.A.
Additive Manufacturing
Topology optimization
Mass : - 40%
Max. Stress : - 40%
Tomlin & Meyer (2011)
Février 2021

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Pierre DUYSINX Liège Créative 14
Additive Manufacturing – Current Limitations
Assessment of constraints caused by
metallic additive manufacturing (LBM,
EBM):
• Minimum and maximum width of walls
• Minimum size of canals (powder
evacuation & insertion of tools)
• Overhanging angle
• Part orientation
• Surface state
• Post machining of working surfaces
• Dimensional precision
• No closed cavities
• Thermal constraints
• Support structure needed and
removed…
Meunier (2015) Meunier (2015)
4 mm
http://www.qualifiedrapidproducts.com/?p=2193 https://hvm.catapult.org.uk
https://3dprint.com/146259/swanso
n-aerotech-metal-am/
Février 2021

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Pierre DUYSINX
• Filtering techniques to remove unacceptable designs
Liège Créative 15
Topology Optimization: Mechanics & Image Processing
Jog & Haber (1990), Zhang &
Duysinx, C&S (2003)
Perimeter Density filter Heaviside filter
Sigmund (1994), Bruns & Tortorelli (2001),
Bourdin (2001)
Guest et al. (2014)
Février 2021

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Pierre DUYSINX Liège Créative 16
Control of Manufacturability: Minimum, Maximum Size, Maximum gap
• Minimum size
• Design domain • Minimum gap
• Maximum size
(Rod in Titanium alloy)
Février 2021

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Pierre DUYSINX Liège Créative 18
Control of Manufacturability: Minimum, Maximum Size, Maximum gap
Heaviside Projection +Maximum Size + Minimum Gap
V*=40%
Février 2021

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Pierre DUYSINX 19
Industrial Design Problem
Jet engine
Oil tank
Oil tank
Objective:
• Minimize the mass of 3 brackets
connecting an oil tank to a jet engine
casing structure.
Design Constraints:
• Strength constraints
• Material connectivity to every provided
fixation (implicit damage resistance)
Manufacturing Constraints:
• Fabrication in a Titanium TiAl6V alloy using
an AM process.
Liège Créative Février 2021

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Pierre DUYSINX 20
Industrial Design Problem : Design domains
Construction of the design domain using
passive elements. (TopOpt + Petsc code)
Liège Créative Février 2021

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Pierre DUYSINX 21
Industrial Design Problem : CAD-CAE all-digital Workflow
(i) Recover full design after symmetry copy, (ii) Generate the STL, (iii) Import into CAD (Siemens-NX v12), (iv)
Fill the holes, (v) Smoothing using reverse engineering tools, (vi) Reconstruct design details, (vii) split the
body, (viii) Mesh the bodies, (ix) Perform the linear finite element analysis, (x) (Virtual) Manufacturing.
Liège Créative Février 2021

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Pierre DUYSINX 22
Industrial Design Problem : Virtual reality
Liège Créative Février 2021

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Pierre DUYSINX Liège Créative 23
Minimum and Maximum length scale control for WAAM designs
Not manufacturable
Close to manufacturability
https://www.youtube.com/wa
tch?v=LAOiMOh5680
Février 2021

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Pierre DUYSINX 24
Manufacturing Constraints – Nozzle size considerations
A B C
Liège Créative Février 2021

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Pierre DUYSINX 25
Manufacturing Constraints – Nozzle size considerations
Liège Créative Février 2021

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Pierre DUYSINX 26
Manufacturing Constraints – Nozzle size considerations
Liège Créative Février 2021

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Pierre DUYSINX 27
Manufacturing Constraints – Nozzle size considerations
Liège Créative Février 2021

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Pierre DUYSINX 28
Manufacturing Constraints – Nozzle size considerations
Liège Créative Février 2021

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Pierre DUYSINX 29
Manufacturing Constraints – Nozzle size considerations
Liège Créative Février 2021

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Pierre DUYSINX 30
Manufacturing Constraints – Nozzle size considerations
Liège Créative Février 2021

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Pierre DUYSINX 31
Manufacturing Constraints – Nozzle size considerations
Liège Créative Février 2021

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Pierre DUYSINX 32
Manufacturing Constraints – Nozzle size considerations
Liège Créative Février 2021

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Pierre DUYSINX 33
Manufacturing Constraints – Nozzle size considerations
Liège Créative Février 2021

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Pierre DUYSINX Liège Créative 34
WHAT’S NEXT?
Février 2021

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Pierre DUYSINX
• Design of high-performance electric machines
Liège Créative 35
ELECTROMAGNETIC APPLICATIONS
ONELAB
Février 2021

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Pierre DUYSINX
• Mastering heat transfer is a key enabler technology in many fields
Liège Créative 37
ENERGY SYSTEMS: COOLING SYSTEMS
10th TOP Webinar, a thematic session on “Topology Optimization of Flow-based Problems”.
Feb 23, 2021, Tuesday. 16:00 – 17:30 pm CET
https://www.youtube.com/watch?v=wZ6EVxlYHrY
Février 2021

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Pierre DUYSINX
• Challenge of design of energy storage and conversion systems
Liège Créative 38
ENERGY SYSTEMS: FUELS CELL DESIGN
Topology Optimization to
determine original designs of the
channel system of the Fuel Cell
Bipolar Plates considering
s.t. :
Physical phenomena
Electrochemical phenomena.
Design constrains
Février 2021

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Pierre DUYSINX Liège Créative 39
CONCLUSIONS
Février 2021

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Pierre DUYSINX
• Topology optimization enables to suggest innovative designs that take
advantage of enhanced capabilities of additive manufacturing
technologies
• Generating designs ready to be printed require accounting for the specific
manufacturing constraints of AM
• Creation of seamless all-digital design chain which is the implementation
of the digital twin concept
• Extension of topology optimization to many domains of engineering:
structural problems, fluids, thermal, electromagnetics…
Liège Créative 40
Conclusions
Février 2021

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Pierre DUYSINX
• Teaming up universities and companies is an essential
enabler for success
Liège Créative 41
Conclusions
Courtesy of Siemens-SAMTECH and SAFRAN
Février 2021

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Pierre DUYSINX
• We want more physics!
• Bigger is better: mega, giga, peta… models
• Topology & Image processing à A.I. / Machine Learning
• Ultimate frontier: non engineering domains: complex problems including
non-deterministic behavioral equations
– Biological systems
– Societal organizations…
Liège Créative 42
Conclusions: our new frontiers
Février 2021

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Pierre DUYSINX Liège Créative 43
Acknowledgments
Acknowledgement
Liege Creative for their kind invitation
Février 2021

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Pierre DUYSINX
• Projects funded by the Walloon Region
– AERO+
– CIMEDE2
– FEDO
– LIGHTCAR
– VIRTUALCOMP
• Projects funded by Europe
– FAFIL
– FRED
– LIGHT VEHICLE 2025
– INOXYPEM
• Projects funded by industrial Partners
– Toyota Motor Corporation
Liège Créative 44
Acknowledgements
Février 2021

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Pierre DUYSINX
Pierre DUYSINX
Automotive Engineering
Aerospace and Mechanics Engineering
University of Liège
Allée de la découverte 13A, building B52
4000 Liège Belgium
Email: P.Duysinx@uliege.be
Tel +32 4 366 9194
Fax +32 4 366 9159
url: www.ingveh.ac.be
www.am.uliege.be
Liège Créative 45
Contact
Février 2021

46. Optimisation topologique et simulation
intégrée pour la fabrication additive
Liège Créative
26 Février 2021
D. Granville, E. Lemaire & F. Duboeuf
Unrestricted | © Siemens 2021 | 2021-02-26 | Siemens Digital Industries Software | Where today meets tomorrow.

47. A little history …
• 1961 : Creation of LTAS at University of Liège
• 1965 : First line of SAMCEF (linear FE analysis)
• 1986 : Creation of Samtech for the industrialisation
and the commercialisation of SAMCEF
• 1990 : First line of SAMCEF Mecano (non-linear analysis,
flexibles mechanisms)
• 2001 : First line of SAMCEF Topol (basis of Design for AM)
• 2002-2010 : Development of SAMTECH Group in Europe, in Asia and US
• 2013 : Acquisition by Siemens
• Today : Samtech Liège ~ 75 people for Simcenter 3D CAE software
development in Liège Science Park
Samtech, Finite Element Analysis of Structures
Liège Science Park
Rue des Chasseurs-Ardennais 8 4031 Angleur

48. Samtech contributes to Siemens Digital Industries Software STS
for the development of 3D modelling & simulation solutions
Digital
Industries
(Software)

49. Samcef, Nastran, Star-CCM+, …
Simcenter 3D
Simcenter™ 3D Portfolio for Predictive Engineering Analytics

50. Siemens Digitalization Strategy in Additive Manufacturing (AM)
Holistic approach for an Integrated Product and Production Lifecycle

51. Siemens simulation workflow for AM
Adapt design
(Convergent
ModelingTM)
Validate
Final part
Topology
optimization
Original
design
Post processing and
inspection
Simulate for AM
Generative design
Light
weighting
Slicing, hatching
printing
Associative - Iterative

52. One integrated CAD/CAM/CAE AM Solution
From requirement driven Generative Design to 3D Printing
Generative
Design
Adaption Product
Validation
Additive
Manufacturing
Checkers
Build Process
Simulation
Part Finishing,
Quality &
Security
Build
Preparation
Digital Twin Product Digital Twin Production
NX for Additive Manufacturing – One integrated Solution
Data and Process Management in Teamcenter
Manufacturing
Execution

53. Simcenter 3D Generative Design
Topology optimization in Simcenter 3D
• Design objectives and constraints.
• Multiple solutions in the same optimization.
• Allows the optimization of components within the system
model.
• Optimization on all finite element types (1D, 2D & 3D).
• Leveraging all load types, including simultaneous
multiple loads.
• Manufacturing constraints and support structures.
• Extension to Boolean operations with Convergent CAD
modeling on faceted bodies.

54. Simcenter 3D AM Build Process Simulation
Challenge:
• Complex Thermo-Mechanical processes lead to distortions
while 3D printing.
• Many test prints have to be performed to find the right
components orientation, correct support structures and
have a good print setup.
Solution:
• Predict distortions using Simcenter 3D Additive
Manufacturing.
• Get information about thermal profile, part distortions,
shrink lines and support failure.
• Fully Integrated into the Additive Manufacturing workflow.
Predict Distortions and Compensate to
“Print first time right”

55. High scrap rate
Build failure
Local
overheating
Recoater
collision
Dimensional
inaccuracy
Material
waste
Microstructure
defects
To predict and prevent AM failures with process simulation

56. Towards reverse engineering in AM through compensation

57. Involvement of Siemens in Walloon and ESA research projects in AM
Generative
Design
Adaption Product
Validation
Additive
Manufacturing
Checkers
Build Process
Simulation
Part Finishing,
Quality &
Security
Build
Preparation
Digital Twin Product Digital Twin Production
NX for Additive Manufacturing – One integrated Solution
Data and Process Management in Teamcenter
Manufacturing
Execution
NX for Additive Manufacturing – One integrated Solution

58. Limit small details with a
minimum length scale
Control bulk region with a
maximum length scale
Prevent failure by considering
maximum stress control
Limit small details with a
minimum length scale
Control bulk region with a
maximum length scale
Prevent failure by considering
maximum stress control
Originates from project
“AERO+”, “ANY-SHAPE4.0”
Consider Manufacturing and Performance requirements
within Topology Optimization for first-time-right design
Embedding AM constraints within Topology Optimization
Design
space
Topology
Optimization
Post-
processing
(CAD/CAE)
Validation
Manufacturing
Service life

59. A joint work with Sonaca (coordinator) and Samtech in the
recently completed collaborative project FASAMA
Design space (optimized)
Preserved regions (frozen)
Topology optimization of satellite fittings Optimal solution for AM
post-processed with
Convergent Modelling®
Meshing and
integration within
the full assembly
Extended validation analysis
on the full assembly
Image credit:
Airbus DS
The Satellite Fitting requires
assembly with additional
insert
Initial design solution
produced by Conventional
Manufacturing process
Optimize design
for AM
?
Acknowledgements
This work has been carried out in the framework of the FASAMA
project supported by:
└► Enhance TO with Performance and AM constraints, post-processing and validation
with other partners: ULB, UCL, CRIBC, GDTech, Sirris
Integration of Topology Optimization into the design cycle for AM

60. End-to-end AM engineering software, including TO and Process simulation
└► Enhance the Siemens’ Digital Innovation Platform for industrialization of AM
Combining generative engineering, topology optimization, predictive analytics,
process simulation, and build preparation to generate designs ready for
production execution.
Development of design methods dedicated to
AM, consolidated on relevant space
applications selected in agreement with ESA
A joint work with Samtech (coordinator) and Sonaca in the
collaborative project Design4AM with ESA
The Design4AM Contract (No. 4000125583/18/NL/BJ) is carried out under
the GSTP program of and funded by the European Space Agency.

61. Minimize mass of the
Launcher Interface Ring
under frequency constraints
and manufacturing constraints
Topology optimization for AM within RTD projects
└► Application to Space structures
Initial design
Optimized design
Image credit: Arianespace
Multi-Component
Model Reduction
Condensation of the environment
in one super-element
Design
space
Topology optimization for AM of a Launcher Interface Ring of a satellite
Mass preserved
during post-
processing
Satisfy
the frequency
requirements
Work lead by Sonaca (coordinator) based on Siemens’ software in the LIRAM activity
(G61A-036QT) carried out with CRM under the GSTP program of and funded by the
European Space Agency.
Full assembly integration
└► Mass reduction = 15%

62. Industrial example in automotive industry

64. Picture source: Bugatti
Siemens and Bugatti innovate the
world’s largest hybrid functional system
consisting of:
• 3D printed hollow and thin-walled bionic
titanium metal components
• Ceramic-coated wound high-modulus
carbon fiber tubes
And achieved:
• Accelerated innovation process by 10X
• Reduced aerodynamic drag
• Lightweighted system by 50%
Pushing the Limits of Car Performance thanks to AM

65. Reimagined Design
for Additive Manufacturing
Shuttle
Bell Crank
Attach Point
Brackets
Carbon Fiber
Tubes
Designed for
Conventional Manufacturing
Reimagining the Bugatti Chiron wing active control system

66. Virtual
product
DigitalTwin
Product
DigitalTwin
Production
DigitalTwin
Performance
Real
product
Virtual
production
Real
production
Automation
Continuousimprovement
Insightsfromperformance
Industrialize Additive Manufacturing:
Design and produce useful parts at scale

68. What’s next ?

69. ESAFORM (April 14-16, 2021) – Liège, Belgium
24th International Conference on Material Forming
Siemens involvement:
• Keynote Speech on ” An end-to-end platform for the industrialization of additive manufacturing “ by Tom
van Eekelen
• Scientific paper entitled “Integration of AM process in design cycle of metallic parts: Application to space
components” by Frédéric Duboeuf
• Siemens as industry sponsor

70. Unrestricted | © Siemens 2021 | 2021-02-26 | Siemens Digital Industries Software | Where today meets tomorrow.
Acknowledgements
This work has been carried out in the framework of the Walloon projects AERO+, FASAMA and
Anyshape4.0 supported by:
Skywin (Aerospace cluster of Wallonia) and/or
Direction générale opérationnelle de l'Économie, de l'Emploi et de la Recherche of Wallonia
The Design4AM contract (No. 4000125583/18/NL/BJ) is carried out under
the GSTP program funded by the European Space Agency.

71. Unrestricted | © Siemens 2021 | 2021-02-26 | Siemens Digital Industries Software | Where today meets tomorrow.
Didier Granville
Directeur Stratégie R&T
Siemens Digital Industries Software
Simulation & Test Solutions – 3D
Samtech s.a.
Liège Science Park
Rue des Chasseurs-Ardennais, 8
4031 Angleur (Belgium)
Mobile : +32 479 333 064
Email : didier.granville@siemens.com
Contact :

72. Merci pour votre attention
ainsi qu’à Liège Créative pour l’organisation
Unrestricted | © Siemens 2021 | 2021-02-26 | Siemens Digital Industries Software | Where today meets tomorrow.

73. BIENVENUE
26/02/2021
Projet fab+
1

74. Présentation Fab+
2
• Acronyme: FAB+
• Titre en clair du projet: Actions complémentaires au projet Factory 4.0 pour le
domaine de l’additive manufacturing
• Soutien sollicité: Formation (Pôle MecaTech)
• Durée du projet: 36 mois
• Financement : Pôles de compétitivité
• Budget : 644.475 €
• Porteur du projet : Technifutur® - TechnoCampus – Campus Automobile

75. Training centers (Leaders):
Partners providing trainings :
Research centers :
Large companies :
Universities :
Small companies :
Consortium du projet Fab+

76. Chaîne de valeur de l’additive Manufacturing
4

77. Structure du projet
5

78. MERCI DE VOTRE ATTENTION
C O N TA C T
Frederik.cambier@technifutur.be • Chef de projet
WWWW.TECHNIFUTUR.BE
6

79. • Les sujets abordés : jumeaux numériques, fondements historiques,
conception assistée par ordinateur, enrichissement des modèles grâce à la
cinématique et aux séquences d’automatisme PLC.
• Objectifs d’apprentissage : donner aux futurs ingénieurs et dessinateur
industriel une vision globale des technologies dites « digital twin » en vue de
les préparer aux défis de l’industrie 4.0.
• Profil du formateur : François Henquet, Ingénieur et Professeur à Helmo
Gramme.
• Profil des participants : ingénieurs et dessinateurs industriels.
• Quand ? Du 1er mars au 15 juin 2021
• Inscription : www.jobsatskills.be
DIGITAL TWIN - MOOC