computer-aided design for additive manufacturing: … · quality control ship to mexico • slice...
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Computer-Aided Design for Additive Manufacturing: Can We Exploit Shape and Material
Complexity Capabilities?
David W. Rosen
George W. Woodruff School of Mechanical EngineeringGeorgia Institute of Technology
Atlanta, GA [email protected] 404-894-9668
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Georgia Tech, Atlanta, GA
Georgia Tech
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Georgia Tech
• 20,000 undergraduate and graduate students
• 800+ faculty• >$300M in research funding• >$300M in research funding• Located in downtown Atlanta• GT was the Olympic Village
for 1996 Summer Games
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Mechanical Engineering
• Includes ME, Nuclear Engr., Health Physics
• 85 faculty• 85 faculty• 1850 undergraduate students• 820 graduate students• 11 Research Groups (CAEDesign, Mfg,
Acoustics, MEMS, Bio, etc.)• Top 5 program
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Overview• Additive Manufacturing
• Cellular Structures
– Construction
– Optimization
• Integrate Materials into Computer-Aided Design
– Simultaneous product-material-process design
– Process-structure-property relationships
• Exposure Controlled Projection Lithography
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Additive Manufacturing• Class of manufacturing processes that build
parts one layer at a time.
• Stereolithography, Selective Laser Sintering, Fused Deposition Modeling, ...
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AM Unique Capabilities
• Shape Complexity
• Material Complexity
• Hierarchical Complexity
• Functional Complexity
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Hearing Aid Shells
CreateImpression
Scan Impression
Create CAD model
Assemble components
Fabricate shell
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Invisalign Manufacturing Process
Timeline
Receiving & Dental Data Treat Aligner Order Entry Laboratory Acquisition Operations Fabrication
SLA MoldFabrication
Prepare & Slice
• STL File Generat ion• Packing (orient & place)• Support Generat ionPrepare & Slice
SLA Build
Quality Control
Ship to Mexico
• Support Generat ion• Slice Data
• Laser (Scanning)• Re-coat (dip in resin)• Sweep (remove excess
resin)• Part Removal & Post-
cure
• Verify test parts• Conduct individual mold
inspect ion
• Kit in transportation box
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Overview• Additive Manufacturing
• Cellular Structures
– Construction
– Optimization
• Integrate Materials into Computer-Aided Design
– Simultaneous product-material-process design
– Process-structure-property relationships
• Exposure Controlled Projection Lithography
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Cellular StructuresWhen modern man builds large loadWhen modern man builds large load--bearing structures, he uses dense solids; bearing structures, he uses dense solids;
steel, concrete, glass. steel, concrete, glass. When nature does the same, she generally uses When nature does the same, she generally uses cellular materialscellular materials; wood, ; wood,
bone, coral. bone, coral. There must be a reason for it.There must be a reason for it.
-- Michael F. Ashby, Anthony Evans, et al.; Michael F. Ashby, Anthony Evans, et al.; Metal Foams: A Design GuideMetal Foams: A Design Guide
Bone Structure Human Skull
[Gibson, 2001]Linear cellular alloy parts [McDowell, 2004]
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Design For Additive ManufacturingLow volume ratio structure
(Adaptive Material Distribution)
Multi-functionality:Structure + Heat Transfer
Multi-functionality: Structure + Acoustics
Combustor liner
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Design and CAD Methods
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CAD Representations
• Purely geometry in CAD systems• Boundary Representation solid modeling
– all geometric details are always represented– 1-2000 geometric entities is limit
• Parametric dimensions– adjustable geometry
• Complicated topology
Freedom of CreationLoughborough Univ.
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Conformal Lattice Structures
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Paramount Industries, Inc.©2009
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UAV & Micro-UAV Examples
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Application to UAV Fuselage
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Size Matching & Scaling (SMS)
1 6
4 3
2
5
Greg Graf’s MS Thesis (April 2009)
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Micro Air Vehicle: Problem Definition
TailFixed support
xy
FTailFMotor
F
19
Fpayload
F Motor(N) 5.9
F Tail (N) 2.7
F Payload (N/mm2) 0.1
Target Volume (mm3) 100,000
Total Unit-Cell Count 214
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Optimized MAV Fuselage
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Overview• Additive Manufacturing
• Cellular Structures
– Construction
– Optimization
• Integrate Materials into Computer-Aided Design
– Simultaneous product-material-process design
– Process-structure-property relationships
• Exposure Controlled Projection Lithography
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Structure-Property Relationship
Har
dnes
s
Distance from surface ( µµµµm)
Har
dnes
s
Low carbon steel Materials Chemistry and Physics, 112:1099-1105, 200 8.
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Motivation
Macro-scale
Decomposition(lower resolution)
CAD system
Property
11 12 1
12 22 2
66 12
0
0
0 0 2
S S
S S
S
σε σ σ
γ
= =
S
Micro-scale
RadonTransform
WaveletTransform
MicrostructureImage
ComputationalMaterials Design
MethodsMicrostructureModel
• Fiber properties• Matrix properties
Material library
DATABASE
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Process Design
Find: process variables
Satisfy: process constraints
Minimize: time, cost
Materials Design
Find: volume fractions, grain size, shape
Satisfy: compatibility constraints
Maximize: energy absorption, mech properties
Part/Product Design
Find: dimension values
Satisfy: stress, strain
Maximize: energy absorption
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Design Problem Formulation
Multi-Objective Optimization Methods
Simultaneous Product / Material / Process Design Me thods
Common Computer-Aided Design Models for Parts and Microstructure
Encoding of microstructure using Surfacelet coefficients
“Zoom-in” and “Zoom-out” operations enabled by Surfacelet model
CAD methods enabled by geometric model based on wav elets and new surfacelets
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150
200
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Process ↔ Structure ↔ Property ↔ Performance
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Dual-Rep Approach• Common geometric model for macro
geometry and microstructure.• Wavelets support multi-resolution
modeling. – Extend to multi-scale.– Represent distributions of material, Ω
δΩ
properties– inefficient in representing curve and
surface singularities.
• Surfacelet: proposed complement to wavelets for representing boundaries.
Ω
( ) ( )( )
− − ⋅ + ⋅ + ⋅ − = + − ⋅ + ⋅
1 2
2
1/ 2 1 1, , , , , 2
2
cos cos cos sin sin
sin cosa b r r
r x y z ba a
r x ya b
b a b a by y
a ar
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Physical CaP-PHB
a) Radon transformθ
µ
b) inverse Radon transforma) Radon transformθ
µ
θ
µ
b) inverse Radon transform
Wavelet decomposition level 4Wavelet decomposition level 4
1 µµµµm1 µµµµm
120~125°135~140°80~95°45~50°
0~3° &
179~180°
θ
µ
c) inverse wavelet transform d) inverse Radon transform
Wavelet decomposition level 4
120~125°135~140°80~95°45~50°
0~3° &
179~180°120~125°135~140°120~125°135~140°80~95°80~95°45~50°45~50°
0~3° &
179~180°0~3° &
179~180°
θ
µ
θ
µ
c) inverse wavelet transform d) inverse Radon transform
Wavelet decomposition level 4
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Three-CaP PHB fiber
• Compute Mechanical Property From microstructure– Resultant elastic modulus matrix*
3.93 0.793 0
– Rule-of mixture : Eeff =3.45 GPa– Inverse rule-of mixture: Eeff =1.14 Gpa
3.93 0.793 0
1 9 0.793 3.26 0
0 0 1.59
e
=
E
*Kalidindi, S.R. and J.R. Houskamp 2007
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IN100 Example
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Computational Materials Design
LaserMelting
Figure courtesy Dr. Surya Kalidindi, Drexel Univers ity
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Overview• Additive Manufacturing
• Cellular Structures
– Construction
– Optimization
• Integrate Materials into Computer-Aided Design
– Simultaneous product-material-process design
– Process-structure-property relationships
• Exposure Controlled Projection Lithography
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Exposure Controlled Projection Lithography
Laser Computer
Collimating
Imaging lens
Resin vat
Engineered diffuser
UV irradiation
Reaction
chamberCured
Part
Glass slide
x
z
DMD
Collimating lens
A more realistic model to predict the cured shape for a given exposure profile is required
Exposure (E) Cured height (z)
??
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ECPL Process Overview
UV LED Source
Beam Conditioning System
Projection System
Resin Chamber
System
DMD
Mirror
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Samples Fabricated with ECPL• Lenses ranging from 100µm to 10mm in a
variety of shapes, with sag heights ranging from 80µm to 300µm
July 3, 2012 33
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Real Time Monitoring System –System Overview
Resin chamber
Detector
Laser
UV Source (365nm)
Beam
system
Beam conditioning
systemDMD™
Projection system
EExposure xposure CControlled ontrolled PProjection rojection LLithographyithography Patent Pending
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Real Time Monitoring System (Discrete point)
Patent Pending
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• Optical Path length, L = nt• Round trip optical path length:(4ngtg + 2nctc)• Change in optical thickness by photocuring, ∆L=2∆nctc
Working Principle
Detectorc c
• Phase shiftØ=2 π ∆L / λØ=4 π ∆nc tc / λ
July 3, 2012 36
Detector
Laser
Patent Pending
tc, nc
• n : refractive index• t : thickness tg, ng
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Experimental Results
July 3, 2012 37
Snapshot of measuring the cured
part from confocal microscopeEstimated
HeightMeasured
Height
105 µm 100 µm
64 µm 66 µm
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Conclusions• Cellular materials are basis for lightweight structure
design: repeated units arrayed along surfaces or fill volumes.
• TrussCreator NX: plug-in for commercial CAD that enables design, FEA, optimization of lattice structure.
• Take Advantage of AM geometric freedom.• Take Advantage of AM geometric freedom.
• Size Matching & Scaling optimization method is efficient (2 variables) and effective.
• Progress toward material (process-structure-property relationships) integrated into Computer-Aided Design systems.
Paramount Industries, Inc.©2009
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Roadmap for Additive Manufacturing Workshop
March 2009, US NSF, ONR funded
http://www.wohlersassociates.com/roadmap2009.html
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Thank you!Acknowledge:
RPMI Industry Members: 3D Systems, CIBA Vision, Ford, Pratt & Whitney, Paramount Industries
NSF IIS-0120663, DMI-0522382, CMMI-1030385
Post-Docs:Scott JohnstonFei Ding
Students:• Hongqing Wang (PhD, 3D Systems)• Benay Sager (PhD, McKinsey)Fei Ding
GT Collaborator:Yan Wang
404-894-9668 [email protected]
• Benay Sager (PhD, McKinsey)• Chris Williams (PhD, Virginia Tech)• Jane Chu (MS, Michelin)• Greg Graf (MS, Rockwell) • Sarah Engelbrecht (MS, Northrop-Grumman)• Namin Jeong, Patrick Chang, Jason Nguyen• Amit Jariwala