Design for Additive Manufacturing
PLM Connections Berlin 2017
Paul Bevan – NX Product Marketing
Realize innovation.Unrestricted © Siemens AG 2017
Unrestricted © Siemens AG 2017
2017.MM.DDPage 2 Siemens PLM Software
What’s limiting your potential?
Performance
Serviceability
Carbon footprint
Weight
Lead time
Design complexity Inventory
Cannot make the shape
Material properties
Speed to innovation Design Manufacturing
Design for Additive Manufacturing
Unrestricted © Siemens AG 2017
2017.MM.DDPage 3 Siemens PLM Software
Impact of additive design to production processes
• End-to-end support to design, optimize and produce parts using additive
manufacturing processes is revolutionizing the way future structures are
developed
• Siemens is leading in the development of next generation software and
processes to enable this shift
Lightweight structure design
& optimization
Performance
Optimization & validation
CES 2017
Divergent 3D 3D Printed Blade Supercar
Siemens PLM Software customer
Requirements driven design
& validation
Build processing
& validation
Convergent ModelingTM technology
Design rules
& validation
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2017.MM.DDPage 4 Siemens PLM Software
Additive unlocks the next frontier of possibility
Transform thinking from ‘Conventional’ to ‘Additive’REIMAGINE PRODUCTS
• Reduce weight, material
• Personalize, customize
• Expand performance
RETOOL MANUFACTURING
• Add complexity for no cost
• Reduce steps, setups, tooling
RETHINK BUSINESS
• Accelerate innovation
• Digital (not physical) inventory
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Design for Additive Manufacturing
REIMAGINE PRODUCTS
• Design with Convergent Modeling TM
• Generative design using topology
optimization
• Lattice structures
• Design rules for manufacturability
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2017.MM.DDPage 6 Siemens PLM Software
Design for Additive Manufacturing
Traditional and new design workflows supported
From Traditional
Prototyping
MakePrepareDesign
MakeModifySimulateScan
Scan to print
MakeValidateOptimizeDesign
Optimize to print
TO…
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Convergent
Modeling™
Technology
Work directly with facets
surfaces and solids
Unlimited flexibility to design
innovative products
No need for reverse engineering
Design for Additive Manufacturing
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2017.MM.DDPage 8 Siemens PLM Software
Convergent Modeling™ technology
Scanning
Polygon
modeling
Topology
optimization
In-process
work piece
Motion
volume
CAE Mesh
Additive & subtractive
manufacturing
Finite element
analysis
Assembly design
Documentation
Tooling
Design without
conversion
10x faster than
traditional methods!
Convergent Modeling
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Design for Additive Manufacturing
Topology
Optimization
All operations in NX CAD
Multiple load cases
Optimized model can be refined with
Convergent Modeling
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2017.MM.DDPage 10 Siemens PLM Software
Lattices
Lightweight components
and structural integrity
Integrated lattice
structure development
Complex geometry
represented as facets
Design for Additive Manufacturing
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2017.MM.DDPage 11 Siemens PLM Software
Design for Additive Manufacturing Topics
• Current Situation
• Siemens Solution
• Common Workflows
• NX Design for Additive Manufacturing (CAD)
• Case Study
• Roadmap
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2017.MM.DDPage 12 Siemens PLM Software
The Current Additive Manufacturing Workflow
Vendor A
Vendor B
Vendor C
Vendor D
Vendor E
Vendor V
Vendor W
Vendor X
Vendor Y
Vendor Z
Design
SoftwareHardware
Vendor V
Vendor W
Vendor X
Vendor Y
Vendor Z
MFG
Software
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2017.MM.DDPage 13 Siemens PLM Software
The Siemens Additive Manufacturing Workflow
Vendor V
Vendor W
Vendor X
Vendor Y
Vendor Z
HardwareSiemens NX
Design using
NX CAD
Analysis
using
Simcenter
Preparation
using NX CAM
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2017.MM.DDPage 14 Siemens PLM Software
Common Workflows
Topology Optimized Parts
Lightweight Structures
Analyze Optimize Redesign Refine
Lattice Import Trim / UniteExport
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Common Workflows
Scanned Geometry (repair, etc.)
Scan Analyze Create/Modify Print
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Common Workflows – Single Environment
Topology Optimized Parts
Lightweight Structures
Analyze Optimize Redesign Refine
Lattice Import Trim / UniteExport
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2017.MM.DDPage 18 Siemens PLM Software
Convergent Modeling
Capability in NX 11
• NX design can work with facets as any other geometry!
• Direct use of scan and polygon/facet data without conversion
• No need for reverse engineering!
• History based modeling with facet geometry
• Booleans/Trims
• Associative wireframe
• …
Business value
• Accelerate concept to production workflows through increased
use of polygon/facet data
Structure built
externally
Integrated into an
NX part
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2017.MM.DDPage 19 Siemens PLM Software
Additive Design Rules & Checking (NX 11.0.1)
Set threshold for
minimum
thickness
Wall thickness
Ensure that part
fits
within the 3D
printer build
volume
Printable volume
Recognize part
regions
that require
support
Overhang angle
Identify fully
enclosed voids
within a part
Wholly enclosed volume
License
• nx_additive_design
Unrestricted © Siemens AG 2017
2017.MM.DDPage 20 Siemens PLM Software
Lightweight structures design
Update NX 11.0.2 accelerated investments
Fill a solid volume with lattices for part light weighting and material reduction while
supporting the required loads
License
• nx_additive_lattice…
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2017.MM.DDPage 21 Siemens PLM Software
Demonstrations
Light Weighted AnalysedPrepareOptimise
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Functional-driven redesign of burner tip
Conventional Burner Design
Burner tip
Disadvantages:
• Nested, ring-shaped fluid channels
• Complex assembly (total length 2 meters)
• Large length of supply system
• Many parts, flanges, welds
• High manufacturing cost / lead time
Total length L = 3.4 m
Unrestricted © Siemens AG 2017
2017.MM.DDPage 24 Siemens PLM Software
Functional-driven redesign of burner tip
Basic Idea:
Use pipe
connections
for Burner tip
to reduce
complexity of
assembly
Tools:
Siemens NX
for CAD-Design
CD-adapco
STAR-CCM+
for CFD simulation.
HEEDS
for parametric
fluid optimization
Redesign
Conventional Burner Design
Burner tip
Disadvantages:
• Nested, ring-shaped fluid channels
• Complex assembly (total length 2 meters)
• Large length of supply system
• Many parts, flanges, welds
• High manufacturing cost / lead time
Total length L = 3.4 m
Unrestricted © Siemens AG 2017
2017.MM.DDPage 25 Siemens PLM Software
Functional-driven redesign of burner tip
Basic Idea:
Use pipe
connections
for Burner tip
to reduce
complexity of
assembly
Tools:
Siemens NX
for CAD-Design
CD-adapco
STAR-CCM+
for CFD simulation.
HEEDS/Optimate
for parametric
fluid optimization
Redesign
New Burner Assembly with redesigned tip
Redesign for Burner tip using AM design freedomConventional Burner Design
Burner tip
Disadvantages:
• Nested, ring-shaped fluid channels
• Complex assembly (total length 2 meters)
• Large length of supply system
• Many parts, flanges, welds
• High manufacturing cost / lead time
Complexity
Targeted use of AM to improve system
Total length L = 3.4 m
Total length L = 1.7 m
Unrestricted © Siemens AG 2017
2017.MM.DDPage 26 Siemens PLM Software
Functional-driven redesign of burner tip
Indicators of
Assembly
Effort
Burner
Assembly with
Conventional
Tip
Burner
Assembly with
Redesigned
Tip
Number of Parts 45-50 19
Number of AM
Parts0 1
Number of
Welding Seams>43 24
Length of Front
Section
1.4m 1.4m
Length of Rear
Section
2.0m 0.3m
Overall Length
of Burner
3.4m 1.7m
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Burner Tip Cooling Water Flow Analysis
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2017.MM.DDPage 28 Siemens PLM Software
HEEDS – Multi-Objective Design Exploration
Optimize with parameter driven CAD or mesh
morphing.
Rapid attainment of optimal designs considering
competing objectives.
Multidisciplinary optimization
High level of automation.
Large ecosystem of integrated solvers
In PLM context, configurations are stored and
managed and can be reused.
2.ProcessAutoma on
3.ScalableComputa on
4.EfficientExplora on5.Sensi vity&Robustness
1.ValidatedCAEModels
mcorespernode
nnodes
CAD Geometry
NX
CFD Analysis
STAR-CCM+
Costing
Excel
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Oxygen and Water Optimized Fluid Dynamics
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NX Roadmap
• Convergent Modeling Improvements
• Lattice structure modeling
• Unit Cell (NX 11.0.2)
• Conformal (NX 12)
• Transitions
• Geometry preparation tools (fixing/manipulation)
• Markings/labels (special + internal)
• 3MF export
• Build orientation optimization
• Multi-color bitmap wrapping
• Parasolid high-performance lattice representation
• AM Electro-mechanical design
• Surface Texture modeling
• Graded color/material modeling
Lightweight
Structures
Graded
Materials