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The Benefits of Topology OptimizationHow to unlock the true potential of Additive Manufacturing
AM-DAGEN 2015 Lars Pursche
Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
About Us
Founded ...
In 1985 as a product design consulting company
Today ...
A global software and technology company focused on simulation and
analytics, product development and advanced computing
solidThinking, Inc. is a wholly-owned subsidiary of Altair
We help businesses succeed
through the development and
application of simulation
technology to accelerate
innovation.
Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
Agenda
Why?Topology / Design Optimization – Concept Design
How?Technology
Who?Industry applications
Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
Two Simple Equations (I)
= min. f(x)
Time
Energy
Material
Waste…
Costs/Price
Weight
75% of the production/product costs
are defined at the design process.
Product Design:
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Nord
Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
Two Simple Equations (II)
= min. f(x)
Energylimited
MovingParts
…
Functio-nality
Perfor-mance
Weight
Energycosts
Product in use:
Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
Problem already solved…
Energy/Motion Weight Material/Performance
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ard
Marq
ue
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Design & CAD
How can a designer come up with the best possible
shape?
Intuition, experience, trial & error,…
How can the engineer draw it in a CAD tool?
CAD tools rely on Boolean Operations of
simple geometric entities
Limited NURBS/freeform capabilities
„Drafting“ something like this can
take weeks with a conventional tool
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Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
Problem
How do I develop extremely
efficient and lightweight
components?
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olfgang M
achnze,
EA
DS
Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
Mechanotransduction
Julius Wolff
(1836-1902)
anatomist and surgeon
Wolff's law
Bone in a healthy person or animal
will adapt to the loads under which
it is placed.
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ikip
edia
Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
geometry loads
loads geometry
Solution
Def. Topology Optimization
mathematical approach/computer based algorithm
that optimizes material layout within a given
design space
for a given set of loads and boundary conditions
Method of Calculation
discretization of the 3D model
highly loaded areas density is increased
less congested areas density is reduced (line of
force)
stresses are distributed evenly
Topology Optimization
of Airbus A380 drop nose
leading edge ribs
Savings:
500 kg just on the leading edge
44% of the original design weight
Copyright © 2015 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
geometry loads
loads geometry
Traditional Design Process
„Real“ Prototype
…ConceptDesign
Concept Design Software
EVOLVE, Rhino, …
DetailedDesign
CAD Software
SolidWorks, Creo, NX, Catia…
Validation(Simulation)
Simulation Tools
HyperWorks, Abaqus, Nastran,…
Copyright © 2015 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
Start with the Solution
Mass = 9.15 Kg
Design Time:
3 Months
Conventional Design ProcessOptimization Driven Design
Process
Mass = 7.5 Kg
Design Time:
3 Weeks
Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
Traditional Design Process vs. Topology Optimization
Traditional Design Process
Development
ConceptDetailed Design Production
Validation &
Prototyping
Documentation
Start with the solution and shorten time to market
Product
Definition
Concept
Design
Validation &
Prototyping
Documentation
Product-
Definition
With Topology Optimization
ProductionDet.
Design
Copyright © 2015 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
Why we look at the Additive Manufacturing?
They are
cool
Elegant design
Structural freedom
Individual design
Democratic design
Complexity is for free
Functional integration
No tooling
Lot size 1
Custom made parts
Spare parts on demand
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ays.c
om
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3D Printing and Topology Optimization
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3D-Printing
Form freedom
Complexity made easy
Individual product
Accelerated production
Topology Optimization
Maximum
performance
Free-form
Individual design
Shortened process
Copyright © 2014 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
Design / Redesign for AM
3D PrintingTopology
OptimizationPerfect
Symbiosis
Perform-ance
increase
Light-weightparts
Strongerparts
Part costreduction
Why should we design/redesign for AM?
AM & TopOpt provides answer to optimal product design
Use the best technology available that leverage the most
out of the complexity for free
If you don’t build the best parts possible, your competition
will do
Replacing the manufacturing
process with 3D printing does not
add any value and/or justify the
costs
Lattice is not redesign
Copyright © 2014 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
LEIBER Group – Air Suspension Bracket Design Study
https://lightmetalage.files.wordpress.com/2015/02/truck-suspension-beam-realised-in-a-special-aluminium-alloy-aluxtremc2ae-leiber-group-gmbh-co.jpg
Copyright © 2014 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
Original Design vs. Optimized Design
55% Mass Reduction
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Gro
up
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Some Of Our Customers
Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
TopOpt
Workflow Topology Optimization (I)
Different Software Tools
Design Space FE Model
„STL Design“
Link to CAM
3D Printing
Link to FEA
Link to CAD
Smoothing Restore
features
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ate
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Workflow Topology Optimization (II)
Integrated Tool INSPIRE
Link to CAM
3D Printing
PolyNURBSDesign Space TopOpt
FEA
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INSPIRE - Workflow
Sketch or Import a
Part/AssemblyAssign Materials and Loads
Generate Ideal ShapeConfirm Performance
(optional)Refine Concept
Defeature the Part
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Start with original CAD design
Export from CAD
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INSPIRE - Example
Topology Optimization Tool
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MTB Rocker Arm - Results
Creative Concept Driven
min S.F. = 1.125
mass = 578 gm
Standard Concept Driven
min S.F. = 1.213
mass = 586 gm
Original
min S.F. = 1.409
mass = 811 gm
Conservative Concept Driven
min S.F. = 1.274
mass = 653 gm
Copyright © 2014 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
Original Design vs. Optimized Design
New Design: 25% Lighter
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Topology Optimization Constrains
General shape (holes)
Design space, non-design space
Minimum & maximum thickness
Mass targets / maximize stiffness
Stress (Factor of Safety)
Frequency constrain
Displacement
Draw Direction (single draw, split draw, extrusion, stamping,…)
Symmetry (symmetric, cyclic, cyclic symmetric,…)
Pattern Repetition
… Sym
metr
y
5 Repetitions
No
Sym
metr
y
20 Repetitions
No symmetry XZ, YZ symmetry
YZ symmetry XZ symmetry
Hollow
sectio
n
Ribs
Without Draw Direction
With Draw Direction
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Armrest and Race Car Air Duct
Example of „Customer Surface“
Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
Design for the Freedom of Additive Manufacturing
-43 %
Topology Optimization
of an Aerospace Part to be productionised by
Additive Manufacturing
[64% weight reduction]
Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
From the Printer into Space
3D Printed Antenna Bracket for
Sentinel-1 Satellite:
43% weight reduction
(from 1.626 kg to 0.936 kg)
Increased Eigen frequency
(70Hz 90 Hz)
Improved static behaviour, strength,
stiffness, stability
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
From the Printer into Space
technology symbiosis:
“topology optimization and
additive manufacturing”
weight cut to half
increased stiffness
reduced stress
minimum design lead time
Source:
Joint project
RUAG, EOS
Antenna Bracket for
Sentinel Satellite
Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
A simulation
driven design
process using
solidThinking
Inspire within the
development chain.
30% Mass Reduction
3x Faster Development
Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
Unlock the
lightweight
potential with
concept
generation
and
organic
interpretation.
32% Weight Reduction
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Steering Upright
Problem Statement
Original design has no structure to resist shear
Improve stiffness while maintaining the original mass and stress
levels
The result was, that the new design was close to 2x stiffer
Copyright © 2013 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
Revolutionizing
the additive
manufacturing
design process for the
world’s first 3D
printed bike frame
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