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Advancements on Design for Additive Manufacturing

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Conference Program
Paid Education

An overview of the state of the art newly introduced capabilities in the areas of Lattice Structure generation, Generative Design, CAD Reconstruction of Generative Design results, generation of validation models for performance simulation, and optimization of print orientation will be presented.

Lattice structures have been used for a long time by nature, now we AM and new CAD capabilities we can use them in our designs.  A pictorial taxonomy of lattice structures such on surface (i.e. iso-grid), 2 ½ D (i.e. honeycomb), 3D beam (i.e. Diamond, Octet) and 3D shell (i.e. Gyroid, Diamond, custom) will be presented.

Generative design is the automatic process to generate optimum feasible designs from a set of performance requirements and design rules. The generated organic designs can be printed using metal additive manufacturing. The Generative Design processes of the modern tools will be presented and demonstrated with three examples from the aerospace industry.  

Over the last three decades, the main bottleneck in the optimization process is the conversion of Generative Design results back to a CAD. Nowadays this is not an issue any more, several tools offer that capability. A simple technique that converts the tessellated Generative Design Results to a B-rep sub-divisional surface models will be demonstrated.

 Another challenge that we recently have overcome is how to simulate the structural or thermal performance of these complex geometries.  A new class of real time simulation tools enable us to simulate intricate lattice structures.  A live example will demonstrate the real-time simulation capabilities.

Learning Objectives:

  • Learn the compelling reasons for use of 3D printed components in light weighting, thermal management and bio-medical applications.
  • Know what are the state-of-the-art capabilities in generating lattice structures
  • Learn how to use Topology Optimization to synthesize optimum lattice structures

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