11

Frontiers of Design for Additive

Manufacturing

Dhruv BhatePhoenix Analysis & Design Technologies, Inc.

Arizona State University

Olaf Diegel, ODD Guitarshttp://www.oddguitars.com/

22

Outline

• Introduction• PADT, ASU• Design for AM

• Vision• Design Frontiers

• State-of-the-Art & Challenges• Key Takeaway

33

Outline

• Introduction• PADT, ASU• Design for AM

• Vision• Design Frontiers

• State-of-the-Art & Challenges• Key Takeaway

44

Phoenix Analysis & Design Technologies, Inc.

PADT & ASUArizona State University

The Polytechnic School

15,000 sq ft., $2M in equipment: the largest AM University research facility in the Southwest Partnership with Concept Laser,

Stratasys, Honeywell and PADT Founded 1994, 75 employees $2M in R&D Equipment

55

Outline

• Introduction• PADT, ASU• Design for AM

• Vision• Design Frontiers

• State-of-the-Art & Challenges• Key Takeaway

66

Metal AM Functional Parts in Aerospace

Exhaust Sensor (RSC Engg.)

Bracket (Airbus) Sensor (GE)

Space Launch Fuel Nozzle (NASA Marshall)

Fuel Nozzle (GE Aviation)

Bracket (Honeywell)

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Cost Reduction

Lead Time Reduction

Supply Chain Simplification

Performance Benefits

New Applications

Business Drivers for AM: SHOULD it be made with AM?

1

2

3

4

5

Rolls Royce Trent XWB

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Is a Part a Good Candidate for AM?

Not everything SHOULD be made with AM.

Not everything CAN be made with AM.

Booth et al, 2016

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Design for Manufacturability

Marc Saunders, Renishawhttps://www.linkedin.com/in/marcsaunders68/

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Role of Design in AM Value

Renishaw

Increasing Value being Driven by DESIGN

1111

133 g 53 g

Drill Guide (Lockheed Martin) Seatbelt Holder (Airbus) Satellite Waveguide (Renishaw)

Bracket (Airbus)

(Altair)

Acetabular Cup

Renishaw

1212

Outline

• Introduction• PADT, ASU• Design for AM

• Vision• Design Frontiers

• State-of-the-Art & Challenges• Key Takeaway

1313

A Moment of Zen

What are the DESIGN IMPLICATIONS of being able to place

ANY MATERIAL

ANYWHERE?

What is “material”?

What is “structure”?

1414

Structure and Material: Traditional

CATIA

M.F. Ashby

1515

Structure is Material is Structure

Bobbio et al (2017)

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Exclusivity Mass Production Functional Optimization

1717

Outline

• Introduction• PADT, ASU• Design for AM

• Vision• Design Frontiers

• State-of-the-Art & Challenges• Key Takeaway

1818

Frontiers of Design for Metal AM1. Topology Optimization

2. Lattice Materials3. Microstructure Design

4. Biomimetic Design

(Macro-scale)

(Meso-scale)

(Micro-scale)

1919

Topology OptimizationDiscrete Approach

Power-Law (SIMP) Approach

Applications: More than just light-weighting!

1

2020

Topology Optimization: Workflow

ANSYS R18

1

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Topology Optimization: Examples

Bracket (Airbus)

Bracket (Honeywell)

1

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Topology Optimization: SOTA & Challenges• State-of-the-Art:

• Commercial software available to enable topology optimization

• Most designs manufacturable with little penalty associated with topology optimization

• Challenges:• Multiple analyses needed• Does not include manufacturing

considerations (“designs the part, not the build")

• Assumes valid material properties (baseline and uncertainty)

• New failure mechanisms not typically considered (thin walls, geometry dependent process sensitivity)

1

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Lattice Materials

Structural

Weight Reduction

Sandwich Cores

Strain Isolation

Vibration Control

Thermal

Heat Exchangers

Flame Arresters

Heat Shields

Fluids

Catalyst Carriers

Packaging

Buoyancy

Biological

Bone Integration

Cell growth

Bio-inspired

http://www.qualifiedrapidproducts.com

http://honeycombceramicsupplier.com/

Made with Additive Manufacturing

Wyss Institute, Harvard

http://www.conceptlaserinc.com/

http://www.altairhyperworks.com/product/OptiStruct/ BMW i3 honeycomb (CFRP) articles.sae.org

http://www.3trpd.co.uk/

Wake Forest (WFIRM) Wyss Institute, Harvard

http://www.foambymail.com/

2

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Approaches for Lattice Implementation in SW• Boolean

– Most CAD software

• Infill– SimpleWare– ANSYS SpaceClaim– intralattice

http://intralattice.com

• Topology Optimization– Altair Optistruct– Solid Inspire

• Generative– Autodesk Within– nTopology

http://insider.altairhyperworks.com/

http://www.autodesk.com/products/within/overview

2

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Lattice Manufacturing Considerations• Minimum Feature Size (approx.)

• Strut [500um (EBM), 150um (Laser-PBF)]

• Pore (varies)

• Support Strategies• Need to avoid internal supports

that cannot be removed• More challenging for

honeycombs, some lattice designs are naturally self-supporting

• Post-Processing

• Inspection

Le et al (2017) Yan et al. (2012)

Ponader et al (2008)

Polished

Unpolished

Process Mod A

Process Mod B

Hollander et al (2006)

2

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Multi-Functionality

NASA Space Fabric

2

Temperature regulationConformal designMechanical protection

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Lattice Materials: SOTA & Challenges

• State-of-the-Art:• Software solutions capable for lattice

generation, claims of optimized lattice design

• Lattice designs actually favorable for many metal AM processes

• Challenges:• Significant challenges with predicting

behavior in lattice materials• High sensitivity to dimensional and

material variation• Very high computational cost

2

2828

Microstructure Design: Graded Materials3

Bobbio et al. (2017)

Ti6Al4V

Invar (~64FeNi)

Low CTE

High Strength

Kasal et al, Honeywell

2929

Microstructure Design: Grain orientation control3

Region 1: <001> columnar Region 2: misorientedRegion 3: <001> & misoriented

Dehoff et al. (2015)

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Microstructure Design: SOTA & Challenges

• State-of-the-Art:• Only in research, no commercial implementation (known)

• Challenges:• Integrity in transition zone• Limitation of layered approach in AM • Limited control on solidification rates

3

31

Biomimicry and AM

Mechanics & Materials

Property

Structure

Computational Simulation

Performance

Design

Nature’s Approaches

3D Printing Manufacturing

Strategy

Function

4

3232

Example: Lattice Materials in Nature4

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Lattice Material Design Possibilities4

McNulty et al (2017)

34

Towards a Multi-functional Biomimetic Lattice Design Framework

4

McNulty et al, 2017

35

Example: ELiSE Bionic Design4

http://elise.de/en

36

Biomimetic Design for AM: SOTA & Challenges• State-of-the-art:

• Point successes have demonstrated potential

• Key source of new design ideas, field on the rise

• Challenges:• Easy to get confused with other forms

of bio-inspiration• Lack of cross-cutting frameworks that

make it easy for non-biologist designers to implement and evaluate biomimetic designs

• Value proposition as a legitimate widespread design methodology still questioned

Airbus

4

3737

Outline

• Introduction• PADT, ASU• Design for AM

• Vision• Design Frontiers

• State-of-the-Art & Challenges• Key Takeaway

3838

Key Takeaway: A Continuum of Design Opportunity

Renishaw

3939

Resources• Design for AM

• Marc Saunders (Renishaw) on LinkedIn • ASME YouTube Series• SAE Web-Seminar (Coming in Spring 2018)

• Topology Optimization for AM• Software (Altair, ANSYS, Autodesk, Dassault, TopOpt…)

• Lattice Materials• Software (Altair, ANSYS, Autodesk, nTopology…)• Research Groups (U Pittsburgh, UT Austin, UofLouisville, ASU…)• SFF Symposium (Conference: annually in August in Austin, TX)

• Microstructure Design• Research Groups (Penn State, ORNL)• SFF Symposium (Conference: annually in August in Austin, TX)

• Biomimetic Design for AM• NASA, Airbus• Research Groups (GTech, UDRI, Purdue, ASU…)• NASA Nature-Inspired Exploration for Aerospace (October 4-6, 2017)

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Thank You!

http://www.padtinc.com/

Dhruv Bhatehttps://www.linkedin.com/in/dhruvbhate/

https://engineering.asu.edu/