Additive Manufacturing Design

Roadmap

Lightweight Design Using

Cellular and Lattice Design Structures and

High-Performance Materials

Multi-Scale Additive Manufacturing Laboratory

Ehsan Toyserkani, Professor, University of Waterloo

Mihaela Vlasea, Assistant Professor, University of Waterloo

2

Research at Multi-Scale Additive Manufacturing Lab

University of Waterloo

3

Feedstock

material

development

and process

optimization

Multi-scale

and

accelerated

modeling and

simulation

platforms

Monitoring

and closed-

loop control of

AM processes

Innovative

AM-made

products

4

Optimized Design

Materials

Material Considerations

Process Constraints

Thermomechanical Considerations

Machine/Software Considerations

Product Digital Design

For lightweighting, cellular topology

function, functionally graded properties

Lattice Structure Design

Generative Design

Generative

design based

on

performance

criteria.

Material Considerations5

Al Alloys

MaterialsDevelopment of process recipes for new materials.

Ti Alloys

Ni Alloys/Superalloys

Ti-6Al-4VTi-5Al-5Mo-5V-3Cr

Invar, CovarInconel

Hastelloy X

Tool Steels

AlSi10Mg

H13, SS

Various Defects, Depending on GeometryDifficulties in not only design, but streamlining

parameter selection.

Product Digital Lattice Design6

Lattice structures for light weighting

Topology optimized shapes for function

Direct 3D Topology Design Indirect 3D Topology Design

CT scan of organic porous matrix

Pore space modelling and quantification

Matrix extraction and layer customization

Process Constraints7

micro meso macro

Industry Roadmap for AM Digital Design

Participation Questions

8

Question 1 – Advanced Design Applications

Based on your organization’s interest in additive manufacturing, which

industry sector has the most pressing need to develop streamlined metal

AM design and manufacturing processes?

9

Low Priority High

1 2 3 4 5

Tooling ⃝ ⃝ ⃝ ⃝ ⃝ Additional

Comments:Automotive ⃝ ⃝ ⃝ ⃝ ⃝

Aerospace ⃝ ⃝ ⃝ ⃝ ⃝

Biomedical ⃝ ⃝ ⃝ ⃝ ⃝

Research ⃝ ⃝ ⃝ ⃝ ⃝

Other ⃝ ⃝ ⃝ ⃝ ⃝

Question 2 – Advanced Material Libraries

Based on your organization’s interest in additive manufacturing, which

materials have the most pressing need to develop streamlined metal

AM material libraries?

10

Low Priority High

1 2 3 4 5

Titanium Alloys ⃝ ⃝ ⃝ ⃝ ⃝ Additional

Comments:Iron Alloys ⃝ ⃝ ⃝ ⃝ ⃝

Nickel Alloys ⃝ ⃝ ⃝ ⃝ ⃝

Aluminium Alloys ⃝ ⃝ ⃝ ⃝ ⃝

Metal Matrix Alloys ⃝ ⃝ ⃝ ⃝ ⃝

Other ⃝ ⃝ ⃝ ⃝ ⃝

Question 3 – Advanced AM Software Tools

The digital design tools in AM are currently shifting focus towards

developing integrative design software. Which areas of design should

be prioritized?

11

Low Priority High

1 2 3 4 5

Topology optimized shapes ⃝ ⃝ ⃝ ⃝ ⃝ Additional

Comments:Lattice and light-weighting ⃝ ⃝ ⃝ ⃝ ⃝

Multi-material composition ⃝ ⃝ ⃝ ⃝ ⃝

Consolidated assemblies ⃝ ⃝ ⃝ ⃝ ⃝

Build conformance verification ⃝ ⃝ ⃝ ⃝ ⃝

Other ⃝ ⃝ ⃝ ⃝ ⃝

Question 4 – Advanced Process Preparation Software

Based on your use of digital tools for preparing data for the AM

process, what are the needs that should be prioritized?

12

Low Priority High

1 2 3 4 5

Interoperability of files

(STL/AMF/3MF)⃝ ⃝ ⃝ ⃝ ⃝ Additional

Comments:

Variable build parameters ⃝ ⃝ ⃝ ⃝ ⃝Tolerance specifications of

surfaces⃝ ⃝ ⃝ ⃝ ⃝

Tolerance specifications for

assemblies⃝ ⃝ ⃝ ⃝ ⃝

Optimized support structures ⃝ ⃝ ⃝ ⃝ ⃝

Other ⃝ ⃝ ⃝ ⃝ ⃝