Minimization of Cost and Print Time of Additive Manufacturing via Topology Optimization

2018 ◽  
Author(s):  
Graeme Sabiston ◽  
Luke Ryan ◽  
Il Yong Kim
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Surface Area ◽  
Large Scale ◽  
Time Factors ◽  
Design Tool ◽  
Support Material ◽  
Manufacturing Operations ◽  
Volume Yield ◽  
The Cost

As the field of design for additive manufacturing continues to evolve and accelerate towards admitting more robust designs requiring fewer instances of user-intervention, we will see the conventional design cycle evolve dramatically. However, to fully take advantage of this emerging technology — particularly with respect to large scale manufacturing operations — considerations of productivity from a fiscal perspective are sure to become of the utmost importance. A mathematical model incorporating the cost and time factors associated with additive manufacturing processes has been developed and implemented as a multi-weighted single-objective topology optimization algorithm. The aforementioned factors have been identified as component surface area and volume of support material. These quantities are optimized alongside compliance, producing a design tool that gives the user the option to choose the relative weighting of performance over cost. In two academic examples, minimization of compliance alongside surface area and support structure volume yield geometries demonstrating that considerable decreases in support material in particular can be achieved without sacrificing significant part compliance.

scholarly journals Guidelines for Topology Optimization as Concept Design Tool and Their Application for the Mechanical Design of the Inner Frame to Support an Ancient Bronze Statue

2021 ◽  
Vol 11 (17) ◽  
pp. 7834
Author(s):  
Abas Ahmad ◽  
Michele Bici ◽  
Francesca Campana
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Early Stage ◽  
Lightweight Design ◽  
Design Tool ◽  
Design Solution ◽  
Design Activity ◽  
Concept Design ◽  
Bronze Statue ◽  
Design Requirements

For the past few decades, topology optimization (TO) has been used as a structural design optimization tool. With the passage of time, this kind of usage of TO has been extended to many application fields and branches, thanks to a better understanding of how manufacturing constraints can achieve a practical design solution. In addition, the advent of additive manufacturing and its subsequent advancements have further increased the applications of TO, raising the chance of competitive manufacturing. Design for additive manufacturing has also promoted the adoption of TO as a concept design tool of structural components. Nevertheless, the most frequent applications are related to lightweight design with or without design for assembly. A general approach to integrate TO in concept designs is still missing. This paper aims to close this gap by proposing guidelines to translate design requirements into TO inputs and to include topology and structural concerns at the early stage of design activity. Guidelines have been applied for the concept design of an inner supporting frame of an ancient bronze statue, with several constraints related to different general design requirements, i.e., lightweight design, minimum displacement, and protection of the statue’s structural weak zones to preserve its structural integrity. Starting from the critical analysis of the list of requirements, a set of concepts is defined through the application of TO with different set-ups (loads, boundary conditions, design and non-design space) and ranked by the main requirements. Finally, a validation of the proposed approach is discussed comparing the achieved results with the ones carried out through a standard iterative concept design.

Laminated-Object-Manufacturing*/Laminated object manufacturing - A method for the production of topological optimization parts

2016 ◽  
Vol 106 (05) ◽  
pp. 354-359
Author(s):  
M. Mottahedi ◽  
P. Zahn ◽  
A. Lechler ◽  
A, Prof. Verl
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Topological Optimization ◽  
Optimal Topology ◽  
Manufacturing Method ◽  
Laminated Object Manufacturing ◽  
Maximum Stiffness ◽  
Global Topology ◽  
The Cost

Topologisch optimierte Bauteile gestatten maximale Steifigkeit bei minimalem Materialeinsatz. Für die Erzeugung solcher Topologien werden meist Algorithmen eingesetzt, die Fertigungseinschränkungen auf Kosten von optimalen Ergebnissen berücksichtigen und keine variablen Materialdichten zulassen. Dieser Fachartikel stellt ein additives Herstellungsverfahren zur Fertigung global optimaler Topologien vor. Als Ergebnis können mittels der ausgewählten Algorithmen Bauteile mit höherer Steifigkeit hergestellt werden.   The optimal topology of components leads to maximum stiffness with minimum material use. To generate these topologies, normally algorithms are employed that tackle manufacturing limitations at the cost of the optimum. This article introduces an additive manufacturing method to enable the production of global topology optimization results. The findings show that by implementing the selected algorithm the stiffness of the components are higher than what could have been produced by conventional techniques.

A Novel Additive Manufacturing File Format for Printed Electronics

2013 ◽  
Author(s):  
Neeraj Panhalkar ◽  
Ratnadeep Paul ◽  
Sam Anand
Keyword(s):  
Additive Manufacturing ◽  
Large Scale ◽  
Printed Electronics ◽  
Form Factors ◽  
Circuit Board ◽  
File Format ◽  
Electronic Components ◽  
Direct Printing ◽  
Manufacturing Information ◽  
The Cost

Additive Manufacturing (AM) based Printed Electronics (PE) is an emerging technique where electronic components and interconnects are printed directly on substrates using a layered technique. The direct printing of the electronic components allows large scale and ultra-thin components to be printed on a wide variety of substrates including glass, silicon and plastic. These attributes make AM based Printed Electronics an invaluable manufacturing technique in the area of electronic sensors and sensor networks where thin, flexible and rugged form factors are very important. However, currently this technology is a labor intensive and manual process with the machine operator using his experience and judgment to slice the CAD file of the part to create 2D layers at different levels. This manual process increases the overall production time as well as the cost of the product and also results in inconsistent quality of parts. A major challenge faced by existing AM based Printed Electronics users for automating this process is the lack of a standard input file format that can be used by different PE machines for producing the components in layers. To leverage the capabilities of both AM and PE processes, a new file format based on the Constructive Solid Geometry (CSG) technique is proposed in this research paper. This file format data will not only include CAD data in the form of CSG primitives and Boolean representation but will also include manufacturing information related to the AM based PE process. The manufacturing information embedded within this new format will include data about the location of the different electronic components such as interconnects, resistors, capacitors, inductors, transistors, memory and substrate, and the materials required for the different components part. Different circuit board components will be represented as primitives or a combination of primitives obtained using CSG technique. In addition to the new file format, a slicing algorithm will also be developed which can be used to create the layers automatically using user inputs. The proposed file format and the slicing algorithm will be explained with the help of a case study.

Topology Optimization for Additive Manufacturing Considering Layer-Based Minimum Feature Sizes

2017 ◽  
Author(s):  
Mikhail Osanov ◽  
James K. Guest
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Manufacturing Process ◽  
Three Dimensional ◽  
Design Tool ◽  
Geometric Constraints ◽  
Layer By Layer ◽  
Simple Modification ◽  
Complex Structural ◽  
Manufacturing Technologies

The rapid advance of additive manufacturing technologies has provided new opportunities for creating complex structural shapes. In order to fully exploit these opportunities, however, engineers must re-think the design process and leverage these new capabilities while respecting manufacturing constraints inherent in various processes. Topology optimization, as a free-from design tool, is a potentially powerful approach to addressing this design challenge provided the manufacturing process is properly accounted for. This work examines geometric constraints related to feature size and the layer-by-layer nature of the manufacturing process. A simple modification to the Heaviside Projection Method, an approach for naturally achieving geometric constraints in topology optimization, is proposed and demonstrated to have clear, understandable impact on three-dimensional optimized beam designs.

scholarly journals Topology optimization subject to additive manufacturing constraints

2021 ◽  
Vol 11 (1) ◽  
Author(s):  
Moritz Ebeling-Rump ◽  
Dietmar Hömberg ◽  
Robert Lasarzik ◽  
Thomas Petzold
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Computational Cost ◽  
Ginzburg Landau ◽  
First Order ◽  
Manufacturing Constraint ◽  
External Forces ◽  
The Cost ◽  
Low Computational Cost ◽  
The Ideal

AbstractIn topology optimization the goal is to find the ideal material distribution in a domain subject to external forces. The structure is optimal if it has the highest possible stiffness. A volume constraint ensures filigree structures, which are regulated via a Ginzburg–Landau term. During 3D printing overhangs lead to instabilities. As a remedy an additive manufacturing constraint is added to the cost functional. First order optimality conditions are derived using a formal Lagrangian approach. With an Allen-Cahn interface propagation the optimization problem is solved iteratively. At a low computational cost the additive manufacturing constraint brings about support structures, which can be fine tuned according to demands and increase stability during the printing process.

Exploration of Various Methods for Cost Considerations in Additive Manufacturing

2017 ◽  
Author(s):  
Andrea Piazza ◽  
Kyle Bielanos ◽  
Beshoy Morkos
Keyword(s):  
Additive Manufacturing ◽  
Small Volume ◽  
Cost Optimization ◽  
Weather Conditions ◽  
Manufacturing Costs ◽  
Part Geometry ◽  
Manufacturing Operations ◽  
Protection Systems ◽  
The Cost

Technology advancements in additive manufacturing allow for useful design optimization, especially in the field of integration (single components with multiple functions). The design process of a component includes considerations of design aspects, such as part geometry with respect to anticipated load conditions, chemical affinity due to possible adverse interaction of non-similar metals, weather conditions not predicted by applied coatings or protection systems and manufacturing design constraints. Due to reduced manufacturing constraints, additive manufacturing brings advantages such as reduced assembly time, higher part performance, and much greater geometric freedom. The following study explores the advantages and quantifies the cost optimization factors, such as manufacturing and assembly costs and material considerations, when assemblies and/or single components are replaced with an additively manufactured part, in mass produced and small volume applications. A relative part replacement cost function will be produced to show the feasibility of changeover to an additive manufactured part, furthermore two case studies will be analyzed and a new case study will be conducted and compared. Additive manufacturing costs, due to the popularization of different techniques, are constantly dropping and, therefore, are becoming valuable options in small to medium scale manufacturing operations as a way to reduce assembly costs and increase design performance.

scholarly journals Multi-solution nature of topology optimization and its application in design for additive manufacturing

2019 ◽  
Vol 25 (9) ◽  
pp. 1475-1481 ◽  
Author(s):  
Hassan Rezayat ◽  
Jared Richard Bell ◽  
Alex J. Plotkowski ◽  
Sudarsanam S. Babu
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Cantilever Beam ◽  
Mechanical Performance ◽  
Design Tool ◽  
Image Correlation ◽  
Content Type ◽  
Fused Deposition ◽  
Starting Point ◽  
Initial Starting

Purpose The purpose of this paper is to introduce the multi-solution nature of topology optimization (TO) as a design tool for additive manufacturing (AM). The sensitivity of topologically optimized parts and manufacturing constraints to the initial starting point of the optimization process leading to structures with equivalent performance is explored. Design/methodology/approach A modified bi-directional evolutionary structural optimization (BESO) code was used as the numerical approach to optimize a cantilever beam problem and reduce the mass by 50 per cent. Several optimized structures with relatively equivalent mechanical performance were generated by changing the initial starting point of the TO algorithm. These optimized structures were manufactured using fused deposition modeling (FDM). The equivalence of strain distribution in FDM parts was tested with the digital image correlation (DIC) technique and compared with that from the modified BESO code. Findings The results confirm that TO could lead to a wide variety of non-unique solutions based on loading and manufacturability constraints. The modified BESO code was able to reduce the support structure needed to build the simple two-dimensional cantilever beam by 15 per cent while keeping the mechanical performance at the same level. Originality/value The originality of this paper lies in introduction and application of the multi-solution nature of TO for AM as a design tool for optimizing structures with minimized features in the overhang condition and the need for support structures.

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