tony norton jim hassberger

The Convergence of Topology Optimization and

Additive Manufacturing

Prepared for: By: Inside 3D Printing Tony Norton & Jim Hassberger

Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.

A story of convergence

Origins

Excitement

Tension Opportunity

Conclusions


Origins

Image from http://jwi.charite.de/en/institute/julius_wolff/

Berlin 1892 Detroit 1993


Origins

University of Michigan Altair University

of Michigan Altair


"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


Design Space

F1 F2

F3

Density plot ’

Early Topology Optimization

Load case Density plot


can change the global layout of the structure

Topology optimization with modified package

small packaging changes

Early Topology Optimization


Excitement

December 1994 September 2012 December

1994 September

2012


Early Adopters


Traditional Design Process

Design Build Verify


Optimized Design Process

Optimize Inspire Innovate


Better parts through optimization


Airliner Wing

“….an innovative rib design, which

resulted in an optimized weight saving

over 500kg per aircraft."


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.


Engine bracket

23% weight savings compared to initial

design, casting constraints to ensure

manufacturability


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


solidThinking Inspire


From DEVELOP3D March 2013


Sketch or Import a Design


Create the “Design Space”


Assign Materials and Loading


See the Ideal Part


Control the Result


Export the Design Proposal


View the Final Design


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.


Opportunity

Technology that can generate designs that

are impossible to make traditionally

Technology that requires a new design approach to achieve the greatest benefit


Opportunity

Synergy

Expanding usage

Disruptive Short run

Non-traditional


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


Conclusion

Origins

Excitement

Reality Opportunity

Conclusion


Conclusions


Topology Optimization + Additive Manufacturing

Easier to apply to designs

Wider range of materials

Appropriate to more

parts


Thank You

Contact: solidThinking, Inc 1820 E. Big Beaver Rd. Troy, MI 48108/ USA