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Journal ArticleDOI

Load-Adapted Design of Generative Manufactured Lattice Structures

01 Jan 2011-Physics Procedia (Elsevier)-Vol. 12, pp 385-392
TL;DR: In this article, a topology optimization is performed as well as the use of periodically arranged lattice structures to avoid shear forces in the struts reducing the stiffness of the lattice.
About: This article is published in Physics Procedia.The article was published on 2011-01-01 and is currently open access. It has received 41 citations till now. The article focuses on the topics: Topology optimization & Shear force.
Citations
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Journal ArticleDOI
TL;DR: In this paper, the ground structure method and density-based topology optimization are used to generate additive manufacturing output, with specific examples given from the fields of health, architecture and engineering.
Abstract: Topology optimization is a technique that allows for increasingly efficient designs with minimal a priori decisions. Because of the complexity and intricacy of the solutions obtained, topology optimization was often constrained to research and theoretical studies. Additive manufacturing, a rapidly evolving field, fills the gap between topology optimization and application. Additive manufacturing has minimal limitations on the shape and complexity of the design, and is currently evolving towards new materials, higher precision and larger build sizes. Two topology optimization methods are addressed: the ground structure method and density-based topology optimization. The results obtained from these topology optimization methods require some degree of post-processing before they can be manufactured. A simple procedure is described by which output suitable for additive manufacturing can be generated. In this process, some inherent issues of the optimization technique may be magnified resulting in an unfeasible or bad product. In addition, this work aims to address some of these issues and propose methodologies by which they may be alleviated. The proposed framework has applications in a number of fields, with specific examples given from the fields of health, architecture and engineering. In addition, the generated output allows for simple communication, editing, and combination of the results into more complex designs. For the specific case of three-dimensional density-based topology optimization, a tool suitable for result inspection and generation of additive manufacturing output is also provided.

361 citations

Journal ArticleDOI
TL;DR: The traditional manufacturing methods of machining and injection molding/casting are reviewed, and the challenges and opportunities related to the emerging additive manufacturing (AM) are highlighted.

240 citations

Journal ArticleDOI
TL;DR: A comprehensive review of the state-of-the-art design methods for additive manufacturing technologies to improve functional performance is provided in this article, where a novel classification method is used to categorize existing design methods.
Abstract: Purpose This paper aims to provide a comprehensive review of the state-of–the-art design methods for additive manufacturing (AM) technologies to improve functional performance. Design/methodology/approach In this survey, design methods for AM to improve functional performance are divided into two main groups. They are design methods for a specific objective and general design methods. Design methods in the first group primarily focus on the improvement of functional performance, while the second group also takes other important factors such as manufacturability and cost into consideration with a more general framework. Design methods in each groups are carefully reviewed with discussion and comparison. Findings The advantages and disadvantages of different design methods for AM are discussed in this paper. Some general issues of existing methods are summarized below: most existing design methods only focus on a single design scale with a single function; few product-level design methods are available for both products’ functionality and assembly; and some existing design methods are hard to implement for the lack of suitable computer-aided design software. Practical implications This study is a useful source for designers to select an appropriate design method to take full advantage of AM. Originality/value In this survey, a novel classification method is used to categorize existing design methods for AM. Based on this classification method, a comprehensive review is provided in this paper as an informative source for designers and researchers working in this field.

149 citations

Journal ArticleDOI

141 citations


Cites methods from "Load-Adapted Design of Generative M..."

  • ...We classify in this category methods based on optimization techniques (parametric and topological) [25,26], those using elementary shapes like lattices structures [41], cellular structures [39], or bionic structures [28] and those defining design features produced by specific AM technologies [30]....

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Journal ArticleDOI
TL;DR: The design method proposed is validated through a case study, and provides an important foundation for the wide adoption of additive manufacturing technologies in the industry.
Abstract: Unlike traditional manufacturing methods, additive manufacturing can produce parts with complex geometric structures without significant increases in fabrication time and cost. One application of additive manufacturing technologies is the fabrication of customized lattice-skin structures which can enhance performance of products while minimizing material or weight. In this paper, a novel design method for the creation of periodic lattice structures is proposed. In this method, Functional Volumes (FVs) and Functional Surfaces (FSs) are first determined based on an analysis of the functional requirements. FVs can be further decomposed into several sub-FVs. These sub-FVs can be divided into two types: FV with solid and FV with lattice. The initial design parameters of the lattice are selected based on the proposed guidelines. Based on these parameters, a kernel based lattice frame generation algorithm is used to generate lattice wireframes within the given FVs. At last, traditional bidirectional evolutionary structural optimization is modified to optimize distribution of lattice struts' thickness. The design method proposed in this paper is validated through a case study, and provides an important foundation for the wide adoption of additive manufacturing technologies in the industry. Display Omitted Both functional roles of solid volume and skin structure are considered.Lattice orientation is introduced that may be adjusted to improve performance.Increased speed of lattice frame generation.Structural stiffness is increased by the proposed optimization algorithm.

137 citations


Cites methods from "Load-Adapted Design of Generative M..."

  • ...Apart from conformal lattice structures, a force flux based design method has been proposed by Teufelhart and Reignhart [26-28]....

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References
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Journal ArticleDOI
TL;DR: In this article, the authors describe which types of laser-induced consolidation can be applied to what type of material, and demonstrate that although SLS/SLM can process polymers, metals, ceramics and composites, quite some limitations and problems cause the palette of applicable materials still to be limited.

1,241 citations

Journal ArticleDOI
TL;DR: A two-scale optimization method is presented at finding optimal configurations of macro structures and micro-structures of cellular material with maximum structural fundamental frequency to meet today's manufacture practice and reduce manufacturing cost.
Abstract: Ultra-light cellular materials exhibit high stiffness/strength to weight ratios and bring opportunity for multifunctional performance. One of their potential applications is to build structure with optimum dynamic performance, which is extremely important for some structural parts in vehicle engineering and attracts a great attention. This paper presents a two-scale optimization method and aims at finding optimal configurations of macro structures and micro-structures of cellular material with maximum structural fundamental frequency. In this method macro and micro densities are introduced as independent design variables for macrostructure and microstructure. Optimizations at two scales are integrated into one system through homogenization theory and base material is distributed between the two scales automatically with optimization model. Microstructure of materials is assumed to be homogeneous at the macro scale to meet today’s manufacture practice and reduce manufacturing cost. Plane structure with homogeneous cellular material and perforated plate are studied. Numerical experiments validate the proposed method and computational model.

180 citations

Journal ArticleDOI
TL;DR: In this article, a manufacturing process chain centered on an augmented three-dimensional printing process was developed to produce steel cellular artifacts with a 270-μm wall thickness and angled trusses and channels that are less than 1 mm in diameter.
Abstract: Cellular materials, metallic bodies with gaseous voids interspersed throughout the solid body, are a promising class of materials that offer high strength accompanied by a relatively low mass. Recent research has focused in the topological design of cellular materials in order to satisfy multiple design objectives. Unfortunately, these design advances have not been met with similar advances in cellular material manufacturing as existing techniques constrain a designer to a predetermined part mesostructure, material type, and macrostructure. In an effort to address these limitations, the authors have developed a manufacturing process chain centered on an augmented three-dimensional printing process. Specifically, metallic cellular materials are made by selectively printing solvent into a bed of spray-dried metal oxide ceramic powder. The resulting green part is then sintered in a reducing atmosphere to chemically convert it to metal. The resultant process has produced maraging steel cellular artifacts featuring a 270-μm wall thickness and angled trusses and channels that are less than 1 mm in diameter.

132 citations

Dissertation
01 Jan 2008
TL;DR: In this paper, the authors present an etude systematique based on the poudres actuellement utilisees dans la Fabrication Directe assistee par laser: Inox 316L, acier d'outillage H13, Inconel 718, CuNi10, Ti grade 2, NiTi and NiTi (-45 µm).
Abstract: L'objectif principal de la these de doctorat presentee dans ce memoire est l'etude de l'interaction d'un faisceau laser de puissance avec des poudres metalliques. Le sujet est d'un grand interet scientifique par sa multidisciplinarite integrant la metallurgie de poudres, la physique thermique, le transfert de chaleur et radiatif, la transformation de phases. En meme temps, le sujet a une signification pratique considerable car la Fabrication Directe par fusion laser selective des poudres (SLM) est une technologie emergente de fabrication d'objets 3D avec une grande valeur ajoutee et de pieces fonctionnelles complexes sur mesure. Une etude systematique a ete realisee sur les poudres actuellement utilisees dans la Fabrication Directe assistee par laser : Inox 316L (-25 µm), acier d'outillage H13 (-25 µm), Inconel 718 (-25 µm), CuNi10 (-25 µm), Ti grade 2 (-25 µm) et NiTi (-45 µm) ; Inox 904L (-16 µm et -7 µm), Inconel 625 (-16 µm), Co212F (CoCr, -31 µm). A partir de ces poudres, des objets plats 2D, des modeles 3D et des pieces fonctionnelles ont ete fabriques. Des recherches experimentales approfondies sur l'interaction laser/matiere sont effectuees, plus particulierement sur l'interaction d'un faisceau laser de haute puissance mobile (0. 3-1. 3x106 W/cm²) avec un systeme complexe de poudres metalliques sur substrat metallique solide. Les strategies de fabrication permettant d'obtenir la densite 100% de pieces resultantes sont identifiees. Les parametres optimaux pour assurer la stabilite du procede SLM sont definis

119 citations