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

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Transcript of "3DPrinting_Suresh"

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