Create Radically Better Products with Design Optimization and 3D Printing

Create Radically Better
Products with Design
Optimization & 3D Printing

q  This webinar will be available afterwards at
www.designworldonline.com & email
q  Q&A at the end of the presentation
q  Hashtag for this webinar: #DWwebinar
Before We Start

Moderator Presenter
Leslie Langnau
Design World
Jaideep Bangal
SolidThinking

Copyright © 2015 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
Agenda
Why?
Topology / Design Optimization – Concept Design
How?
Technology
Who?
Industry applications

3D Printing: Changing Design and Manufacturing

They are
cool
Elegant
design
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 Additive Manufacturing?

Why design / redesign components?
To make sure that an added value is designed into the part
•  Extreme performance increase
•  Lightweight parts
•  Stronger parts
•  Part cost reduction

Traditional CAD systems rely on Boolean operations
“Subtractive Designing”
Traditional Design
pictures by courtesy of Laser Zentrum Nord

“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

Topology Model Setup
•  A volume or design space was
created around the component
such that:
o  It encompassed the allowable space
the bracket structure could occupy
o  Mounting interfaces to the component
and the mating structure were not part
of the design space (grey).
•  Constraints:
o  The mounting interface to the
structure were fixed.
o  Displacement constraint of .00015“
•  A mass model was attached to
the component mounting points.

Topology results
Images of a few
different
topology runs.
The bottom left
is the
smoothened
version of the
chosen design.

Preliminary Structural Analysis
Within the topology analysis program, structural analysis is
performed on the smoothened model to predict results. These are
shown below and are within specification. The resulting mass of
the topology model is .08lbs
Displ: 3.4e-5in
1st Mode: 515 Hz

CAD Model
The smoothened model was then brought into CAD and a solid representative
model was produced. Note that the solid model is not an exact replica and
need not be, but structure for the load paths need to be similar.

Final Design
•  Further refinements were made to
facilitate post machining operations
and part stability.
•  Part weight: .11 lbs.
•  Original part weight: .17 lbs
•  Weight Redux: 35%

Evolve 2015 Traditional CAD
Design Comparison

Evolve 2015 Traditional CAD
363 Hz 1st Frequency 313 Hz
539 psi (3.72 MPa) Max Stress 534 psi (3.68 MPa)
8.62e-5 in (2.19e-6 m) Max Displacement 9.62e-5 in (2.44e-6 m)
.100 lb (.045 kg) Weight .108 lb (.049 kg)
8 hours Design Time 24 hours
Performance Comparison

Optimized AlSi12 metal printed bracket (40% reduction in weight)
Print speed
18 hour /each if build just 1 part
12 hours /each if build full (9 pc) plate

Design and
manufacture
based on intent
55% Mass Reduction

Unlock the lightweight
potential of AM with
concept generation
and
organic interpretation.
32% Weight Reduction

Unlock the
lightweight potential
of ALM with concept
optimization
for EADS IW
326g
918g
- 64%
“it allowed us to maximize the
weight saving benefits of the ALM
process.”
Jon Meyer EADS Innovation Works

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.
It 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 à 90 Hz)
•  Improved static behaviour,
strength, stiffness, stability
From the Printer into Space

Design
Interpretation
Geometry
creation
Evaluation
of design
Geometry
validation
From the Printer into Space
Baseline
CAD
Manufacturing 1Image courtesy of RUAG Space
Design Process for AM

How to …
Inspire Driven Design
unlocks the potential of
Additive Manufacturing
Explore Inspire’s seamless
process and see
how you can benefit!
-43 %

Questions?
Leslie Langnau
Design World
llangnau@wtwhmedia.com
Twitter: @DW_3DPrinter
Jaideep Bangal
SolidThinking
jbangal@solidthinking.com
Request a Free Trial!
www.solidThinking.com

Thank You
q  This webinar will be available at
designworldonline.com & email
q  Tweet with hashtag #DWwebinar
q  Connect with Design World
q  Discuss this on EngineeringExchange.com

Create Radically Better Products with Design Optimization and 3D Printing

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