Tony Norton Jim Hassberger

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Technology

The Convergence of
Topology Optimization and
Additive Manufacturing
Prepared for: By:
Inside 3D Printing Tony Norton & Jim Hassberger

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A story of convergence
Origins
Excitement
TensionOpportunity
Conclusions

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Origins
Image from http://jwi.charite.de/en/institute/julius_wolff/
Berlin 1892 Detroit 1993

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Origins
University of Michigan Altair
University
of Michigan Altair

Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
"Wolff’s Law"
Das Gesetz der Transformation der
Knochen (The Law of Transformation
of Bone), 1892.
"As a consequence of primary shape
variations and continuous loading, or
even due to loading alone, bone
changes its inner architecture
according to mathematical rules and,
as a secondary effect and governed by
the same mathematical rules, also
changes its shape."
Images from http://jwi.charite.de/en/institute/julius_wolff/
Das Gesetz der Transformation
der Knochen

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Design Space
F1 F2 F3
Density plot
Early Topology Optimization
Load case Density plot

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can change the global layout of the structure
Topology optimization with modified package
small packaging changes
Early Topology Optimization

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Excitement
December 1994 September 2012
December
1994
September
2012

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Early Adopters

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Traditional Design Process
Design Build Verify

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Optimized Design Process
Optimize Inspire Innovate

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Better parts through optimization

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Airliner Wing
“….an innovative rib design, which
resulted in an optimized weight saving
over 500kg per aircraft."

Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
Crane Boom
The component’s dead weight was
reduced by approximately 20 % and
load capacity was increased by up to
400 kg. Apart from its higher handling
efficiency, the redesigned stick now
provides improved protection for
equipment attached to it.

Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
Engine bracket
23% weight savings compared to initial
design, casting constraints to ensure
manufacturability

Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
Tension – Topology Optimization
Often used by
experienced FE
analysts late in
product development
Offers the biggest
benefit when used
early in the process
by designers

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

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From DEVELOP3D March 2013

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Sketch or Import a Design

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Create the “Design Space”

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Assign Materials and Loading

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See the Ideal Part

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Control the Result

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Export the Design Proposal

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View the Final Design

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Tension – Additive Manufacturing
3D printing changes the calculus of manufacturing by optimizing for batches of 1.3D printing changes the calculus of
manufacturing by optimizing for batches of one.

Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
Opportunity
Technology that can
generate designs that
are impossible to
make traditionally
Technology that
requires a new design
approach to achieve
the greatest benefit

Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
Opportunity
Synergy
Expanding
usage
Disruptive Short run
Non-
traditional

Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
Agenda for Altair Event Tomorrow in Turin
Martin Muir, EADS
Multidisciplinary Optimisation of Business Jet MED Hinge for Production by Additive
Manufacturing
Wolfgang Machunze, EADS
Topology Design of a Metallic Load Introduction Bracket Manufactured by ALM
Simon Merkt, RWTH Aachen/ILT Fraunhofer
Digital Photonic Production - Optimization Potentials by Laser Based Manufacturing
Jannis Kranz, TUHH
Structural Optimization and Laser Additive Manufacturing in Lightweight Design:
Barriers and Chances

Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
Conclusion
Origins
Excitement
RealityOpportunity
Conclusion

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

Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
Topology Optimization + Additive Manufacturing
Easier to
apply to
designs
Wider
range of
materials
Appropriate
to more
parts

Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
Thank You
Contact:
solidThinking, Inc
1820 E. Big Beaver Rd.
Troy, MI 48108/ USA

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Tony Norton Jim Hassberger

1. The Convergence of Topology Optimization and Additive Manufacturing Prepared for: By: Inside 3D Printing Tony Norton & Jim Hassberger

5. Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved. "Wolff’s Law" Das Gesetz der Transformation der Knochen (The Law of Transformation of Bone), 1892. "As a consequence of primary shape variations and continuous loading, or even due to loading alone, bone changes its inner architecture according to mathematical rules and, as a secondary effect and governed by the same mathematical rules, also changes its shape." Images from http://jwi.charite.de/en/institute/julius_wolff/ Das Gesetz der Transformation der Knochen

7. Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved. can change the global layout of the structure Topology optimization with modified package small packaging changes Early Topology Optimization

13. Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved. Airliner Wing “….an innovative rib design, which resulted in an optimized weight saving over 500kg per aircraft."

14. Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved. Crane Boom The component’s dead weight was reduced by approximately 20 % and load capacity was increased by up to 400 kg. Apart from its higher handling efficiency, the redesigned stick now provides improved protection for equipment attached to it.

15. Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved. Engine bracket 23% weight savings compared to initial design, casting constraints to ensure manufacturability

16. Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved. Tension – Topology Optimization Often used by experienced FE analysts late in product development Offers the biggest benefit when used early in the process by designers

26. Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved. Tension – Additive Manufacturing 3D printing changes the calculus of manufacturing by optimizing for batches of 1.3D printing changes the calculus of manufacturing by optimizing for batches of one.

27. Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved. Opportunity Technology that can generate designs that are impossible to make traditionally Technology that requires a new design approach to achieve the greatest benefit

29. Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved. Agenda for Altair Event Tomorrow in Turin Martin Muir, EADS Multidisciplinary Optimisation of Business Jet MED Hinge for Production by Additive Manufacturing Wolfgang Machunze, EADS Topology Design of a Metallic Load Introduction Bracket Manufactured by ALM Simon Merkt, RWTH Aachen/ILT Fraunhofer Digital Photonic Production - Optimization Potentials by Laser Based Manufacturing Jannis Kranz, TUHH Structural Optimization and Laser Additive Manufacturing in Lightweight Design: Barriers and Chances

32. Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved. Topology Optimization + Additive Manufacturing Easier to apply to designs Wider range of materials Appropriate to more parts

Tony Norton Jim Hassberger

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Tony Norton Jim Hassberger