Design Faster and Lighter: Applications of Topology Optimization In Additive Manufacturing - Americas ATC 2015 Workshop

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Design Faster and Lighter: Applications of Topology Optimization in Additive Manufacturing

ATC 2015 Jaideep Bangal

Copyright © 2015 solidThinking, Inc. Proprietary and Confidential. All rights reserved.

Agenda

Why?Topology / Design Optimization – Concept Design

How?Technology

Who?Industry applications


3D Printing: Changing Design and Manufacturing


They are

cool

Elegant design

Structural freedom

Individual design

Democratic design

Complexity is for free

Functional integration

No tooling

Lot size 1

Custom made parts

Spare parts on demand

Why we look at the Additive Manufacturing?


Why design / redesign components?

To make sure that an added value is designed into the part

• Extreme performance increase

• Lightweight parts

• Stronger parts

• Part cost reduction


Traditional CAD systems rely on Boolean operations

“Subtractive Designing”

Traditional Design

pictures by courtesy of Laser Zentrum Nord


“Drafting” something like this

can take weeks with a conventional system:

Efficient Design

pictures by courtesy of Laser Zentrum Nord


What is Topology Optimization?

Topology optimization is a mathematical approach that optimizes material

layout within a given design space under given operating conditions.


Start with original CAD design


Create Package Space and Load Cases


Inspire Concept Shape


Explore Different Designs / Shapes


Validate Inspire Concept Shape / Proposal


Inspire Results back into CAD


Original Design vs. Inspire Design

New Design

25% Lighter


3D Printing and Topology Optimization

Images courtesy of shapeways.com

3D-Printing

Form freedom

Complexity made easy

Individual product

Accelerated production

Topology Optimization

Maximum

performance

Free-form

Individual design

Shortened process


Application in Broad Industries


Application in Broad Industries


Design and

manufacture

based on intent

55% Mass Reduction


Unlock the

lightweight

potential of AM with

concept

generation

and

organic

interpretation.32% Weight Reduction


Unlock the

lightweight

potential of ALM

with concept

optimization

for EADS IW

326g

918g

- 64%

“it allowed us to maximize the weight

saving benefits of the ALM process.”

Jon Meyer EADS Innovation Works

Unlock the

lightweight

potential of AM with

concept

optimization

and

organic interpretation

at LZN

- 26 %


Empire Cycles World’s First 3D Printed Titanium Bike Frame

Spareparts made to

order, make products

live longer.

It reduces material

use and helps to

make them profitable.

Source:

“How Additive

Manufacturing Changed

the World of Engineering”

Dr.-Ing. Olaf Rehme,

Dipl.-Ing. Martin Schäfer

Siemens AG, Corporate

Technology

Material Substitution

Functionality Integration

Minimum material usage


3D Printed Antenna Bracket for

Sentinel-1 Satellite:

• 43% weight reduction

(from 1.626 kg to 0.936 kg)

• Increased Eigen frequency

(70Hz 90 Hz)

• Improved static behaviour, strength,

stiffness, stability

From the Printer into Space


Design

Interpretation

Geometry

creation

Evaluation

of design

Geometry

validation

From the Printer into Space

Baseline

CAD

Manufacturing 1

Image courtesy of RUAG Space

Design Process for AM


How to …

Inspire Driven Design

unlocks the potential of

Additive Manufacturing

Explore Inspire’s

seamless

process and see

how you can benefit!

-43 %


Question and Answers

Visit us at solidThinking

www.solidThinking.com

http://www.solidthinking.com/

Documents

Design Faster and Lighter: Applications of Topology Optimization In Additive Manufacturing - Americas ATC 2015 Workshop