design faster and lighter:applications of topology optimization in additive manufacturing

Prepared for By

An Company

Design Faster and Lighter: Applications of Topology

Optimization in Additive Manufacturing

ATC 2015 Jaideep Bangal

Prepared for By

An Company

Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.

When topology optimization is utilized to generate designs for additive

manufacturing, many exciting new benefits present themselves

(lightweight parts, stronger parts, no wasted materials, cost savings,

etc.). This presentation will answer a number of questions. What is

topology optimization? Why does topology optimization makes sense

for additive manufacturing? How does topology optimization work?

Who has been applying topology optimization? Why should topology

optimization be on a designer’s desktop? What are the future

opportunities? This presentation will include multiple real-world

examples of companies using topology optimization to design for and

enhance the benefits of additive manufacturing.

Temp slide - abstract


Agenda

Why?

Topology / Design Optimization – Concept Design

How

Technology

Who

Industry applications

Copyright © 2014 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

3D Printing: Changing Design and Manufacturing


They are

cool

fancy stuff

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?


To make sure that an added value is designed into the part

• extreme performance increase

• Lightweight parts

• Stronger parts

• Part cost reduction

• Functional integration

Why design / redesign components?


“Drafting” something like this

can take weeks with a conventional system:

Efficient Design

pictures by courtesy of Laser Zentrum Nord


What is Topology Optimization?

Topology optimization is a mathematical approach that optimizes material

layout within a given design space under given operating conditions.


Start with original CAD design


Create Package Space and Load Cases


Inspire Concept Shape


Explore Different Designs / Shapes


Validate Inspire Concept Shape / Proposal


Inspire Results back into CAD


Original Design vs. Inspire Design

New Design: 25% Lighter


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


Application in Broad Industries


Design and

manufacture

based on intent

55% Mass Reduction


Unlock the

lightweight

potential of AM with

concept

generation

and

organic

interpretation.32% Weight Reduction


The Femur Stool

Designing organic

structures for ALM

with concept

optimization‘Visuals and product design

by Assa Ashuach Studio’


Unlock the

lightweight

potential of ALM

with concept

optimization

for EADS IW

326g

918g

- 64%

“OptiStruct allowed us to maximize

the weight saving benefits of the ALM

process.”

Jon Meyer EADS Innovation Works


Engineering ability

Front loading

Only the right assumptions lead to the desired result


Unlock the

lightweight

potential of AM with

concept

optimization

and

organic interpretation

at LZN

- 26 %


Empire Cycles World’s First 3D Printed Titanium Bike Frame


Spareparts made to

order, make products

live longer.

OptiStruct 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


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


Conceptual Optimization

Design Interpretation

Geometry creation

Evaluation of designGeometry validation

From the Printer into Space

Baseline CAD

Manufacturing 1

Image courtesy of RUAG Space

Design Process for AM


Simulation Driven Design unlocks the potential of Additive Manufacturing

Explore Altair's seamless

process and see

how you can benefit!

Visit us at:

www. altair.de

[email protected]

How to …

design faster and lighter:applications of topology optimization in additive manufacturing

Technology

topology optimization

company design

given design space

original cad design

parts spare parts

efficient design pictures

design redesign components

additive manufacturing