Mock-up of AM analysis user interface with alternative designs compared.
This project addresses gaps in the current additive manufacturing (AM) design-to-print workflow by enabling the insertion of decision tools and AM-aware design tools into Siemens NX CAD system and within the Senvol database.
Additive manufacturing (AM) part design iteration, analysis, optimization, prototyping and production methods, and tools have all relied on a patchwork of techniques and CAD data formats which have evolved from conventional material and machining. Training for design engineers to learn how to design components specifically for AM and software tools to facilitate and enhance these designs are needed to fully exploit the advantages of AM.
The goal of this project is to address gaps in the current AM design-to-print workflow by enabling the insertion of decision tools and AM-aware design tools into an existing CAD system and database. The project seeks to create a comprehensive knowledge base that codifies good design practices; a web-based portal that educates designers on design for AM (DFAM) and provides guidance on process capabilities and limitations; a suite of CAD-integrated design-for-manufacture tools; a methodology enabling accurate finite element analysis (FEA) modeling coupled with process parameter variables; and DFAM course materials for technical colleges and universities.
The DFAM knowledge and corresponding web-based portal is being compiled for both powder bed fusion (PBF) and fused deposition modeling (FDM) technologies. CAD-integrated design tools include DFAM analysis and design exploration tools for lattice structure generation, topology optimization, and part consolidation developed for both polymer and metal technologies. Finally, an anisotropic and dynamic process, coupled with material characterization, is being developed for the FDM technology. Relevant process variables, such as localized toolpath direction and void content, are being generated within the DFAM ecosystem for input in the creation of a part specific FEA material model.
Other Project Participants
- MSC Software
- University of Texas-Austin
- University of Texas-Arlington
- Lockheed Martin
- GKN Woodward
- Northrop Grumman,
- Rockwell Collins
- Textron Aviation
- General Motors (GM)
- U.S. Department of Defense
- National Science Foundation
- U.S. Department of Energy