create radically better products with design optimization and 3d printing

Create Radically Better Products with Design

Optimization & 3D Printing

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Before We Start

Moderator Presenter

Leslie Langnau Design World

Jaideep Bangal SolidThinking

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 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

Topology Model Setup •  A volume or design space was

created around the component such that: o  It encompassed the allowable space

the bracket structure could occupy o  Mounting interfaces to the component

and the mating structure were not part of the design space (grey).

•  Constraints: o  The mounting interface to the

structure were fixed. o  Displacement constraint of .00015“

•  A mass model was attached to the component mounting points.

Topology results Images of a few different topology runs. The bottom left is the smoothened version of the chosen design.

Preliminary Structural Analysis Within the topology analysis program, structural analysis is performed on the smoothened model to predict results. These are shown below and are within specification. The resulting mass of the topology model is .08lbs

Displ: 3.4e-5in 1st Mode: 515 Hz

CAD Model The smoothened model was then brought into CAD and a solid representative model was produced. Note that the solid model is not an exact replica and need not be, but structure for the load paths need to be similar.

Final Design •  Further refinements were made to

facilitate post machining operations and part stability.

•  Part weight: .11 lbs. •  Original part weight: .17 lbs •  Weight Redux: 35%


Evolve 2015 Traditional CAD

Design Comparison


Evolve 2015 Traditional CAD 363 Hz 1st Frequency 313 Hz

539 psi (3.72 MPa) Max Stress 534 psi (3.68 MPa) 8.62e-5 in (2.19e-6 m) Max Displacement 9.62e-5 in (2.44e-6 m)

.100 lb (.045 kg) Weight .108 lb (.049 kg) 8 hours Design Time 24 hours

Performance Comparison

Optimized AlSi12 metal printed bracket (40% reduction in weight)

Print speed 18 hour /each if build just 1 part 12 hours /each if build full (9 pc) plate


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 à 90 Hz)

•  Improved static behaviour, strength, stiffness, stability

From the Printer into Space


Conceptual Optimization

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 %

Questions? Leslie Langnau Design World [email protected] Twitter: @DW_3DPrinter

Jaideep Bangal SolidThinking [email protected]

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