Review on design and structural optimisation in additive manufacturing: Towards next-generation lightweight structures
TL;DR: In this article, the state-of-the-art developments in the design for additive manufacturing (DfAM) and structural optimisation, becomes vital for successfully shaping the future AM-landscape.
About: This article is published in Materials & Design.The article was published on 2019-12-05 and is currently open access. It has received 330 citations till now. The article focuses on the topics: Generative Design & Topology optimization.
Citations
More filters
TL;DR: In this article, a holistic concept of material-structure-performance integrated additive manufacturing (MSPI-AM) is proposed to cope with the extensive challenges of laser-based additive manufacturing.
Abstract: BACKGROUND Metallic components are the cornerstone of modern industries such as aviation, aerospace, automobile manufacturing, and energy production. The stringent requirements for high-performance metallic components impede the optimization of materials selection and manufacturing. Laser-based additive manufacturing (AM) is a key strategic technology for technological innovation and industrial sustainability. As the number of applications increases, so do the scientific and technological challenges. Because laser AM has domain-by-domain (e.g., point-by-point, line-by-line, and layer-by-layer) localized forming characteristics, the requisite for printing process and performance control encompasses more than six orders of magnitude, from the microstructure (nanometer- to micrometer-scale) to macroscale structure and performance of components (millimeter- to meter-scale). The traditional route of laser-metal AM follows a typical “series mode” from design to build, resulting in a cumbersome trial-and-error methodology that creates challenges for obtaining high-performance goals. ADVANCES We propose a holistic concept of material-structure-performance integrated additive manufacturing (MSPI-AM) to cope with the extensive challenges of AM. We define MSPI-AM as a one-step AM production of an integral metallic component by integrating multimaterial layout and innovative structures, with an aim to proactively achieve the designed high performance and multifunctionality. Driven by the performance or function to be realized, the MSPI-AM methodology enables the design of multiple materials, new structures, and corresponding printing processes in parallel and emphasizes their mutual compatibility, providing a systematic solution to the existing challenges for laser-metal AM. MSPI-AM is defined by two methodological ideas: “the right materials printed in the right positions” and “unique structures printed for unique functions.” The increasingly creative methods for engineering both micro- and macrostructures within single printed components have led to the use of AM to produce more complicated structures with multimaterials. It is now feasible to design and print multimaterial components with spatially varying microstructures and properties (e.g., nanocomposites, in situ composites, and gradient materials), further enabling the integration of functional structures with electronics within the volume of a laser-printed monolithic part. These complicated structures (e.g., integral topology optimization structures, biomimetic structures learned from nature, and multiscale hierarchical lattice or cellular structures) have led to breakthroughs in both mechanical performance and physical/chemical functionality. Proactive realization of high performance and multifunctionality requires cross-scale coordination mechanisms (i.e., from the nano/microscale to the macroscale). OUTLOOK Our MSPI-AM continues to develop into a practical methodology that contributes to the high performance and multifunctionality goals of AM. Many opportunities exist to enhance MSPI-AM. MSPI-AM relies on a more digitized material and structure development and printing, which could be accomplished by considering different paradigms for AM materials discovery with the Materials Genome Initiative, standardization of formats for digitizing materials and structures to accelerate data aggregation, and a systematic printability database to enhance autonomous decision-making of printers. MSPI-oriented AM becomes more intelligent in processes and production, with the integration of intelligent detection, sensing and monitoring, big-data statistics and analytics, machine learning, and digital twins. MSPI-AM further calls for more hybrid approaches to yield the final high-performance/multifunctional achievements, with more versatile materials selection and more comprehensive integration of virtual manufacturing and real production to navigate more complex printing. We hope that MSPI-AM can become a key strategy for the sustainable development of AM technologies. Download high-res image Open in new tab Download Powerpoint Material-structure-performance integrated additive manufacturing (MSPI-AM). Versatile designed materials and innovative structures are simultaneously printed within an integral metallic component to yield high performance and multifunctionality, integrating in parallel the core elements of material, structure, process, and performance and a large number of related coupling elements and future potential elements to enhance the multifunctionality of printed components and the maturity and sustainability of laser AM technologies.
386 citations
TL;DR: In this article, the authors discuss the progress to date in the improvement of the fatigue performance of cellular structures manufactured by additive manufacturing, especially metal-based, providing insights and a glimpse to the future for fatigue-tolerant additively manufactured architected cellular materials.
Abstract: Additive manufacturing of industrially-relevant high-performance parts and products is today a reality, especially for metal additive manufacturing technologies. The design complexity that is now possible makes it particularly useful to improve product performance in a variety of applications. Metal additive manufacturing is especially well matured and is being used for production of end-use mission-critical parts. The next level of this development includes the use of intentionally designed porous metals - architected cellular or lattice structures. Cellular structures can be designed or tailored for specific mechanical or other performance characteristics and have numerous advantages due to their large surface area, low mass, regular repeated structure and open interconnected pore spaces. This is considered particularly useful for medical implants and for lightweight automotive and aerospace components, which are the main industry drivers at present. Architected cellular structures behave similar to open cell foams, which have found many other industrial applications to date, such as sandwich panels for impact absorption, radiators for thermal management, filters or catalyst materials, sound insulation, amongst others. The advantage of additively manufactured cellular structures is the precise control of the micro-architecture which becomes possible. The huge potential of these porous architected cellular materials manufactured by additive manufacturing is currently limited by concerns over their structural integrity. This is a valid concern, when considering the complexity of the manufacturing process, and the only recent maturation of metal additive manufacturing technologies. Many potential manufacturing errors can occur, which have so far resulted in a widely disparate set of results in the literature for these types of structures, with especially poor fatigue properties often found. These have improved over the years, matching the maturation and improvement of the metal additive manufacturing processes. As the causes of errors and effects of these on mechanical properties are now better understood, many of the underlying issues can be removed or mitigated. This makes additively manufactured cellular structures a highly valid option for disruptive new and improved industrial products. This review paper discusses the progress to date in the improvement of the fatigue performance of cellular structures manufactured by additive manufacturing, especially metal-based, providing insights and a glimpse to the future for fatigue-tolerant additively manufactured architected cellular materials.
238 citations
TL;DR: It is shown that in the research of topology optimization for additive manufacturing, the integration of material, structure, process and performance is important to pursue high-performance, multi-functional and lightweight production.
224 citations
TL;DR: In this paper, an eXtended defect zone (XDZ) describing the propensity for local plasticity during fatigue around a defect has been shown through numerical analysis to be a good indicator of the ranking of the threat to fatigue caused by differently located manufacturing defects.
192 citations
TL;DR: In this paper, the authors focus on process planning including build orientation, slicing, and path planning, as well as the definition of process parameter selection from a single track to multi-track and multilayer, and finally geometric features from a thinwall to lattice structures with several case studies.
173 citations
Cites background from "Review on design and structural opt..."
...Exclusion topics as reviewed elsewhere include mass transfer phenomena and topology optimization modelling [20], design methodologies and software [21,22], microstructural and materials related WAAM [23–25], in-process monitoring and in-machine surface metrology [26,27],mechanical properties [9,11,28], design for AM and application of WAAM [29–31]....
[...]
References
More filters
TL;DR: The PSC algorithm as mentioned in this paper approximates the Hamilton-Jacobi equations with parabolic right-hand-sides by using techniques from the hyperbolic conservation laws, which can be used also for more general surface motion problems.
13,020 citations
Book•
01 Aug 1988TL;DR: The linear elasticity of anisotropic cellular solids is studied in this article. But the authors focus on the design of sandwich panels with foam cores and do not consider the properties of the materials.
Abstract: 1. Introduction 2. The structure of cellular solids 3. Material properties 4. The mechanics of honeycombs 5. The mechanics of foams: basic results 6. The mechanics of foams refinements 7. Thermal, electrical and acoustic properties of foams 8. Energy absorption in cellular materials 9. The design of sandwich panels with foam cores 10. Wood 11. Cancellous bone 12. Cork 13. Sources, suppliers and property data Appendix: the linear-elasticity of anisotropic cellular solids.
8,946 citations
TL;DR: In this article, the authors present a methodology for optimal shape design based on homogenization, which is related to modern production techniques and consists of computing the optimal distribution in space of an anisotropic material that is constructed by introducing an infimum of periodically distributed small holes in a given homogeneous, i.i.
Abstract: Optimal shape design of structural elements based on boundary variations results in final designs that are topologically equivalent to the initial choice of design, and general, stable computational schemes for this approach often require some kind of remeshing of the finite element approximation of the analysis problem. This paper presents a methodology for optimal shape design where both these drawbacks can be avoided. The method is related to modern production techniques and consists of computing the optimal distribution in space of an anisotropic material that is constructed by introducing an infimum of periodically distributed small holes in a given homogeneous, i~otropic material, with the requirement that the resulting structure can carry the given loads as well as satisfy other design requirements. The computation of effective material properties for the anisotropic material is carried out using the method of homogenization. Computational results are presented and compared with results obtained by boundary variations.
5,858 citations
TL;DR: In this paper, the authors derived upper and lower bounds for the effective elastic moduli of quasi-isotropic and quasi-homogeneous multiphase materials of arbitrary phase geometry.
Abstract: Variational principles in the linear theory of elasticity, involving the elastic polarization tensor, have been applied to the derivation of upper and lower bounds for the effective elastic moduli of quasi-isotropic and quasi-homogeneous multiphase materials of arbitrary phase geometry. When the ratios between the different phase moduli are not too large the bounds derived are close enough to provide a good estimate for the effective moduli. Comparison of theoretical and experimental results for a two-phase alloy showed good agreement.
5,224 citations
Book•
17 Sep 2011
TL;DR: In this article, the authors proposed a topology optimization by distribution of isotropic material for truss structures with anisotropic materials, based on the topology design of truss structure.
Abstract: 1 Topology optimization by distribution of isotropic material- 2 Extensions and applications- 3 Design with anisotropic materials- 4 Topology design of truss structures- 5 Appendices- 6 Bibliographical notes- References- Author Index
4,881 citations