Tony Norton Jim Hassberger

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Tony Norton Jim Hassberger

  1. 1. The Convergence ofTopology Optimization andAdditive ManufacturingPrepared for: By:Inside 3D Printing Tony Norton & Jim Hassberger
  2. 2. Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.A story of convergenceOriginsExcitementTensionOpportunityConclusions
  3. 3. Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.OriginsImage from http://jwi.charite.de/en/institute/julius_wolff/Berlin 1892 Detroit 1993
  4. 4. Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.OriginsUniversity of Michigan AltairUniversityof Michigan Altair
  5. 5. Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved."Wolff’s Law"Das Gesetz der Transformation derKnochen (The Law of Transformationof Bone), 1892."As a consequence of primary shapevariations and continuous loading, oreven due to loading alone, bonechanges its inner architectureaccording to mathematical rules and,as a secondary effect and governed bythe same mathematical rules, alsochanges its shape."Images from http://jwi.charite.de/en/institute/julius_wolff/Das Gesetz der Transformationder Knochen
  6. 6. Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.Design SpaceF1 F2 F3Density plotEarly Topology OptimizationLoad case Density plot
  7. 7. Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.can change the global layout of the structureTopology optimization with modified packagesmall packaging changesEarly Topology Optimization
  8. 8. Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.ExcitementDecember 1994 September 2012December1994September2012
  9. 9. Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.Early Adopters
  10. 10. Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.Traditional Design ProcessDesign Build Verify
  11. 11. Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.Optimized Design ProcessOptimize Inspire Innovate
  12. 12. Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.Better parts through optimization
  13. 13. Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.Airliner Wing“….an innovative rib design, whichresulted in an optimized weight savingover 500kg per aircraft."
  14. 14. Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.Crane BoomThe component’s dead weight wasreduced by approximately 20 % andload capacity was increased by up to400 kg. Apart from its higher handlingefficiency, the redesigned stick nowprovides improved protection forequipment attached to it.
  15. 15. Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.Engine bracket23% weight savings compared to initialdesign, casting constraints to ensuremanufacturability
  16. 16. Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.Tension – Topology OptimizationOften used byexperienced FEanalysts late inproduct developmentOffers the biggestbenefit when usedearly in the processby designers
  17. 17. Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.solidThinking Inspire
  18. 18. Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.From DEVELOP3D March 2013
  19. 19. Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.Sketch or Import a Design
  20. 20. Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.Create the “Design Space”
  21. 21. Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.Assign Materials and Loading
  22. 22. Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.See the Ideal Part
  23. 23. Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.Control the Result
  24. 24. Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.Export the Design Proposal
  25. 25. Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.View the Final Design
  26. 26. Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.Tension – Additive Manufacturing3D printing changes the calculus of manufacturing by optimizing for batches of 1.3D printing changes the calculus ofmanufacturing by optimizing for batches of one.
  27. 27. Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.OpportunityTechnology that cangenerate designs thatare impossible tomake traditionallyTechnology thatrequires a new designapproach to achievethe greatest benefit
  28. 28. Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.OpportunitySynergyExpandingusageDisruptive Short runNon-traditional
  29. 29. Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.Agenda for Altair Event Tomorrow in TurinMartin Muir, EADSMultidisciplinary Optimisation of Business Jet MED Hinge for Production by AdditiveManufacturingWolfgang Machunze, EADSTopology Design of a Metallic Load Introduction Bracket Manufactured by ALMSimon Merkt, RWTH Aachen/ILT FraunhoferDigital Photonic Production - Optimization Potentials by Laser Based ManufacturingJannis Kranz, TUHHStructural Optimization and Laser Additive Manufacturing in Lightweight Design:Barriers and Chances
  30. 30. Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.ConclusionOriginsExcitementRealityOpportunityConclusion
  31. 31. Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.Conclusions
  32. 32. Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.Topology Optimization + Additive ManufacturingEasier toapply todesignsWiderrange ofmaterialsAppropriateto moreparts
  33. 33. Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.Thank YouContact:solidThinking, Inc1820 E. Big Beaver Rd.Troy, MI 48108/ USA

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