#3DPrintConf

1. 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

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"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."

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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.

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Engine bracket
23% weight savings compared to initial
design, casting constraints to ensure
manufacturability

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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

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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.

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Opportunity
Technology that can
generate designs that
are impossible to
make traditionally
Technology that
requires a new design
approach to achieve
the greatest benefit

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Opportunity
Synergy
Expanding
usage
Disruptive Short run
Non-
traditional

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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

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Conclusion
Origins
Excitement
RealityOpportunity
Conclusion

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Conclusions

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Topology Optimization + Additive Manufacturing
Easier to
apply to
designs
Wider
range of
materials
Appropriate
to more
parts

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Thank You
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