One of the great potentials of 3D printing additive manufacturing is to reshape the product design so that many of the products we are familiar with are almost completely different from the original "long". With less material, and even better mechanical properties, additive manufacturing opens up a whole new dimension for designers.
In the manufacturing process of additive manufacturing, designers do not need to worry too much about the limitations of processing. They can pay more attention to the performance goals of this product. Can I design a product with the same functional characteristics and use less material? How to get cost savings? It is the flexibility of additive manufacturing that makes parts more complex, organic and lighter while meeting performance requirements. In this issue, we will further understand hand-in-hand simulation and additive manufacturing through the analysis of Dassault simulation expert Subham Sett.
Figure 1 The general goal of topology optimization is to optimize the distribution of materials in a given design space. For basic optimization tasks, material volume is a constraint. For a given material volume (target volume or target weight), maximum stiffness must be achieved.
Topology optimization is an important means of shortening the additive manufacturing design process by topology optimization to identify and remove materials that do not affect the rigidity of the part. The topological approach determines the optimal material distribution in a defined design area: including boundary conditions, pre-tension, and load targets. Figure 1 through Tosca software can be used to create organic designs that use less material while meeting all functional requirements and constraints. In a larger design space (gray area), based on Abaqus iterative nonlinear finite element analysis, the materials needed to meet the performance requirements are presented. In addition, Tosca software can be co-simulated with other third-party finite element solvers to optimize parameter-free optimization of complex structural components based on nonlinear analysis.
Tosca software takes into account the limitations of traditional manufacturing in the traditional manufacturing mode of casting and injection mold design. So, in the additive manufacturing mode, do you need some special considerations? Take NASA's aircraft and a board enclosure on the satellite. Considering the average cost of launch, the cost of launching a pound of material into space is close to $10,000. The topology-optimized model was manufactured by FDM fused deposition 3D printing technology and the weight was reduced by nearly one-third.
The factors to be considered include not only the additive manufacturing process itself, but also the 3D printed products and the parts manufactured by the traditional process need to be assembled. Tosca software simulation optimization process needs to consider the design of the joint parts of the two parts. There is also a need to consider the resolution choices for printing for the additive manufacturing process. You also need to choose a conservative limit to avoid gaps or cracks in the printing process. In addition, most additive manufacturing processes require a support structure that, whether merely serving as a support or providing a heat transfer path, adds cost to the material and printing overhead. Minimize overhangs to avoid support structures and reduce the need for support by optimizing the build direction and increase cost efficiency.
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