Optimized part design exploiting the design freedom enabled by additive manufacturing.
This project seeks to develop an integrated design suite with built-in design aids for various AM manufacturability requirements.
Additive manufacturing (AM) processes enable parts to be designed largely without regard to manufacturability constraints, however existing CAD/CAE software packages have not taken full advantage of the enormous design freedom made possible by AM techniques.
The goal of this project is to develop an integrated design suite with built-in design aids for various AM manufacturability requirements and new topology optimization capabilities for high potential AM applications.
The technical approach consists of developing and implementing design aids and cost models for both the EOS direct metal laser sintering (DMLS) process and the ExOne binder jetting process (BJP) into the ANSYS SpaceClaim module. New cellular structure design optimization (CSDO) functionalities which include natural frequency, thermal cooling, and simultaneous constrained stress and thermal cooling optimization are being developed. The approach also involves implementing the new and existing CSDO functionalities, including minimum compliance and constrained stress optimization, into the ANSYS topology optimization module. The developing integrated design tool is being applied to optimize the design of several high potential applications, such as lightweight laser systems, support structures for AM parts, and lightweight multifunctional components for motion control systems, missiles, and engines.
Other Project Participants
- United Technologies Research Corporation (UTRC)
- Materials Sciences Corporation
- ExOne Corporation
- Marcus Machinery
- Oberg Industries
- Texas A&M University
- U.S. Department of Defense
- National Science Foundation
- U.S. Department of Energy