design faster and lighter: applications of topology optimization in additive manufacturing -...
TRANSCRIPT
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Prepared for By
An Company
Design Faster and Lighter: Applications of Topology Optimization in Additive Manufacturing
ATC 2015 Jaideep Bangal
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Copyright © 2015 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
Agenda
Why?Topology / Design Optimization – Concept Design
How?Technology
Who?Industry applications
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3D Printing: Changing Design and Manufacturing
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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?
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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
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Traditional CAD systems rely on Boolean operations
“Subtractive Designing”
Traditional Design
pictures by courtesy of Laser Zentrum Nord
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“Drafting” something like this
can take weeks with a conventional system:
Efficient Design
pictures by courtesy of Laser Zentrum Nord
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What is Topology Optimization?
Topology optimization is a mathematical approach that optimizes material
layout within a given design space under given operating conditions.
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Start with original CAD design
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Create Package Space and Load Cases
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Inspire Concept Shape
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Explore Different Designs / Shapes
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Validate Inspire Concept Shape / Proposal
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Inspire Results back into CAD
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Original Design vs. Inspire Design
New Design
25% Lighter
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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
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Application in Broad Industries
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Application in Broad Industries
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Design and
manufacture
based on intent
55% Mass Reduction
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![Page 21: Design Faster and Lighter: Applications of Topology Optimization In Additive Manufacturing - Americas ATC 2015 Workshop](https://reader030.vdocument.in/reader030/viewer/2022032507/55ceef04bb61ebdb7f8b4738/html5/thumbnails/21.jpg)
Unlock the
lightweight
potential of AM with
concept
generation
and
organic
interpretation.32% Weight Reduction
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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
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Unlock the
lightweight
potential of AM with
concept
optimization
and
organic interpretation
at LZN
- 26 %
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Empire Cycles World’s First 3D Printed Titanium Bike Frame
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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
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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
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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
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How to …
Inspire Driven Design
unlocks the potential of
Additive Manufacturing
Explore Inspire’s
seamless
process and see
how you can benefit!
-43 %
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Question and Answers
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www.solidThinking.com