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3DPrinting_Suresh 3DPrinting_Suresh Presentation Transcript

  • 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.com)
  • 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 has exceeded our capacity to design” - Opening remark, 2013 ISAT/DARPA Workshop Conventional CAD?
  • 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 FEA: Incredibly slow!
  • 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 multiply (Brodtkorb 13)
  • 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 PareTO Nvidia GTX 480, 1.5 GB 4 mins UW-Madison
  • 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 with 480M GPU
  • PareTO: Maximize Strength Optimal design for Maximizing Strength (30% vol fraction) Time taken: 14 mins Laptop CPU: I7 with 480M GPU Optimal topology
  • 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.ersl.wisc.edu suresh@engr.wisc.edu