Design Optimization Strategy for Multifunctional 3D Printing

An optimization based design methodology for the additive manufacture of multifunctional parts (for example, a structure with embedded electronic/electrical systems and associated conductive paths) is presented. This work introduces a coupled optimization strategy where Topology Optimization (TO) is combined with an automated placement and routing approach that enables determination of an efficient internal system configuration. This permits the effect of the incorporation of the internal system on the structural response of the part to be taken into account and therefore enables the overall optimization of the structure-system unit. An example test case is included in the paper to evaluate the optimization strategy and demonstrate the methods effectiveness. The capability of this method allows the exploitation of the manufacturing capability under development within the Additive Manufacturing (AM) community to produce 3D internal systems within complex structures.Mechanical Engineerin

Оценка прогнозируемой эффективности декомпозиции изделия при его послойном изготовлении

Представлены результаты исследования влияния структурной обратимой декомпозиции изделия на рациональное использование рабочего пространства послойного построения установки аддитивных технологий. Выполнялось исследование возможностей оценки прогнозируемой эффективности применения декомпозиции на основе статистического анализа распределения элементарных объемов (воксельной 3D-модели) изделия по подпространствам, получаемым путем разбиения рабочего пространства. Апробация оценки и предложенных показателей осуществлялась на основе моделей промышленных изделий.The results of a study of the effect of structural reversible decomposition of product on rational use of workspace volume of additive manufacturing plant are presented. The evaluation possibilities of predicted efficiency of the decomposition on the basis of statistical analysis of the distribution of elementary volumes (voxel 3D-model) of product on subspaces obtained by dividing the workspace were investigated. Testing of evaluation and proposed indicators was carried out on the basis of industrial product models

3D printing part orientation optimization: discrete approximation of support volume

In three-dimensional (3D) printing, due to the geometry of most parts, it is necessary to use extra material to support the manufacturing process. This material must be discarded after printing, so its reduction is essential to minimize manufacturing time and cost. An important parameter that must be defined before starting the printing process is the part orientation, which has repercussions on the quality, deposition path, and post-processing among others. Usually, the user sets up this parameter arbitrarily, so this paper takes advantage of it on optimization techniques and proposes an approximation of the volume be covered by the support material, which depends directly on the angle of the part to be printed and its geometry. Among mono-objectives optimization strategies, this work focuses on five of them. Their performance is compared by two metrics: support volume and execution time. Then, the best result is compared with commercial software

Development of fuel filter cap of comet diesel engine using structural optimization technique and additive manufacturing

As market competition and computational technologies grow, engineering design and development process heavily relies on the computer modelling, simulation and prototype manufacturing to accelerate the development cycles and to save the cost. This article intends to use finite element method as a structural optimization tool and 3D additive manufacturing for manufacturing of prototype to optimize the weight and strength of fuel filter cap of 5HP, 1500 rpm water cooled comet diesel engine within the lesser time cycle. The developed fuel filter cap is manufactured through the stages of pattern making using 3D printing machine, casting of cap by sand casting process, finishing operations and subsequently tested on the comet diesel engine testing set up. The development work has resulted in 48.67% stress reduction and 17.87% reduction in the weight of the fuel filter cap