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3dprintconfny14

3dprintconfny14

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  • 1. New Design Paradigms for 3D Printing Krishnan Suresh Associate Professor Mechanical Engineering
  • 2. CAD SketchPad (MIT; 1963)
  • 3. CAD: Underlying Philosophy Influenced by traditional manufacturing Controlled Complexity 3D Printing: Complexity is Free
  • 4. Simple vs Complex 3D Printing Geometric complexity is free Controlled Complexity
  • 5. Why Complexity? Why design complex parts? - Aesthetics - Optimal - Assembly-free (3ders.com) (mmsonline.com) (bathsheba.com)
  • 6. Optimal Design & Complexity ? Stronger and lighter (but more complex) (3ders.com)
  • 7. How to design such optimal parts? Optimal Designs ~ Complex & Beautiful “For the first time, our capacity to manufacture has exceeded our capacity to design” - Opening remark, 2013 ISAT/DARPA Workshop Conventional CAD?
  • 8. Example Remove material, but keep it stiff! A B ?
  • 9. Visualize in 3-D
  • 10. Idea!
  • 11. Idea!!
  • 12. Idea!!
  • 13. Level Set
  • 14. 2D Example PareTO Software: www.ersl.wisc.edu
  • 15. Michell Truss Optimal & Beautiful
  • 16. Topology Optimization (3D) 60% weight 50% weight 16 6% weight
  • 17. Hook Design • Strong • Lite • Controlled complexity Geometric complexity is free
  • 18. New design tools for 3d printing will emerge
  • 19. Simulation Questions Conventional FEA: Incapable! Can I print? Will it break?
  • 20. Optimal Design Design Space Finite Element Analysis (FEA) Optimal? Change Topology No 100’s of iterations! 20 Conventional FEA: Incredibly slow!
  • 21. Optimal Design Size Optistruct Intel Xeon, 12 core, 92 GB (180,60,30) 20 hours
  • 22. New Simulation Methods for High Performance Computing
  • 23. CPU vs. GPU Cache RAM GPU Memory 50~1000 GFLOP GPUCPU 10~50 GFLOP (1~12 cores) (100~2000 cores)
  • 24. GPU Off-the-shelf PCI hardware ($100 - $500) Vendors: NVidia, ATI,
  • 25. Trends in Computing Computing Speed Memory Speed Memory starved computation Takes more time to fetch 2 numbers than to multiply (Brodtkorb 13)
  • 26. New simulation tools for 3d printing will emerge
  • 27. Optimal Designs PareTO Intel i7, 8 cores, 8 GB 42 mins Size Optistruct Intel Xeon, 12 core, 92 GB (180,60,30) 20 hours PareTO Nvidia GTX 480, 1.5 GB 4 mins UW-Madison
  • 28. PareTOWorks (SolidWorks Integrated) suresh@engr.wisc.edu
  • 29. Real-time Design
  • 30. Topology Optimization
  • 31. Topology Optimization Minimize weight within design-space subject to stress constraints under 4 different load-conditions!
  • 32. 450 Entries!
  • 33. PareTO: Maximize Stiffness Optimal design for Maximizing Stiffness (30% vol fraction) Time taken: 8 mins Laptop CPU: I7 with 480M GPU
  • 34. PareTO: Maximize Strength Optimal design for Maximizing Strength (30% vol fraction) Time taken: 14 mins Laptop CPU: I7 with 480M GPU Optimal topology
  • 35. Going beyond 3D Printing
  • 36. Bridge Problem
  • 37. Bridge Problem V = 30% 1 min 10 secs
  • 38. Airframe Seat
  • 39. Wheel Support
  • 40. Designing Braces for Buildings
  • 41. Acknowledgements Graduate Students NSF UW-Madison Kulicke and Soffa Luvata Design Concepts Publications available at www.ersl.wisc.edu suresh@engr.wisc.edu