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Create Radically Better Products with Design
Optimization & 3D Printing
q This webinar will be available afterwards at www.designworldonline.com & email
q Q&A at the end of the presentation q Hashtag for this webinar: #DWwebinar
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
Copyright © 2015 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
3D Printing: Changing Design and Manufacturing
Copyright © 2015 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
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?
Copyright © 2015 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
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
Copyright © 2015 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
Traditional CAD systems rely on Boolean operations “Subtractive Designing”
Traditional Design
pictures by courtesy of Laser Zentrum Nord
Copyright © 2015 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
“Drafting” something like this can take weeks with a conventional system:
Efficient Design
pictures by courtesy of Laser Zentrum Nord
Copyright © 2015 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
What is Topology Optimization? Topology optimization is a mathematical approach that optimizes material layout within a given design space under given operating conditions.
Copyright © 2015 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
Start with original CAD design
Copyright © 2015 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
Create Package Space and Load Cases
Copyright © 2015 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
Inspire Concept Shape
Copyright © 2015 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
Explore Different Designs / Shapes
Copyright © 2015 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
Validate Inspire Concept Shape / Proposal
Copyright © 2015 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
Inspire Results back into CAD
Copyright © 2015 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
Original Design vs. Inspire Design
New Design
25% Lighter
Copyright © 2015 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
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
Copyright © 2015 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
Application in Broad Industries
Copyright © 2015 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
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%
Copyright © 2015 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
Evolve 2015 Traditional CAD
Design Comparison
Copyright © 2015 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
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
Copyright © 2015 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
Design and
manufacture
based on intent
55% Mass Reduction
Copyright © 2015 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
Unlock the lightweight
potential of AM with
concept generation
and
organic interpretation.
32% Weight Reduction
Copyright © 2015 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
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 %
Copyright © 2015 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
• 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
Copyright © 2015 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
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
Copyright © 2015 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
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
Copyright © 2015 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
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 llangnau@wtwhmedia.com Twitter: @DW_3DPrinter
Jaideep Bangal SolidThinking jbangal@solidthinking.com
Request a Free Trial!
www.solidThinking.com
Thank You q This webinar will be available at
designworldonline.com & email
q Tweet with hashtag #DWwebinar
q Connect with Design World
q Discuss this on EngineeringExchange.com
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