Additive Manufacturing

Design & Engineering Symposium

Paradigmenwechsel
Innovation Intelligence in der Konstruktion und Entwicklung
 Technology Symbiosis
Additive Manufacturing
& Topology Optimization
Mirko Bromberger
25.11.2014 - euromold, Aussteller Forum
Innovation Intelligence
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Technology.
Technology Inspires Design
 Our vision is to radically change
the way organizations design products
and make decisions.
Additive Manufacturing (AM)
 One of the benefits:
total design freedom
With design freedom comes the ability to create
extremly efficient & lightweight designs

Conventional AM Design
25% lighter
 (so this is how ALM
technologies can help
saving our planet)
 3
challenges when designing for AM
 1
How can a designer come up with the best
possible shape?
 Solution #1:

Biomimicry Software
Underlying Technology:
 Manufacturing constraints
Topology optimization provides the most efficient structure for a given load situation, but for traditional
manufacturing designers always have to trade performance for manufacturability!

Unconstrained
Symmetry
Performance

Draw Direction
Member Size
Cyclic Repetition

Manufacturing
Constraints
 Technology symbiosis
Topology optimization provides the most efficient structure for a given load situation, with added
manufacturing designers no more have to trade performance for manufacturability

Unconstrained
Symmetry
Performance

Draw Direction
Member Size
Cyclic Repetition

Manufacturing
Constraints
 2
How can the engineer draw it in a CAD system?
can take weeks with a conventional system:
 Solution #2:

Polymesh Design Technology

 3
How to consider the NEW Manufacturing Constraints?
Types of support

Downward facing surfaces

Angled surfaces and holes

http://www.manufacturingthefuture.co.uk/design-guidelines/
Examples
 Flyable 3D
st

installed on
a A350
918g

Redesign of a A320
326g
nacelle hinge bracket for
AM
Case Study available www.altair.com

Jon Meyer, EADS Innovation Works

Engineering ability

Front loading
Only the right assumptions lead to the desired result
 manufacturing of lightweight
structures in TiAl6V4: a design

ILAS, Hamburg
Presentation a Altair Technology Conference 2014

Weight: -26%
 AFTER
BEFORE Optimization

RUAG Pioneers 3D Printing for Space

Press Release, RUAG, Oct 27 2014
3D Printed Antenna Bracket for Sentinel-1 Satellite
RUAG Pioneers 3D Printing for Space

Final bracket weight: 0.936 kg,

original weight:1.626 kg

Final design validated for static

behaviour, strength, stiffness,
stability. All design criteria satisfied.

1st prototype is printed and will be

tested for qualification.
 The Femur Stool
Designing organic structures for
AM with concept optimization

by Assa Ashuach
 Summary

AM technologies enable innovative design approaches

Use of optimization software can significantly reduce

structural weight and lead time

AM and topology optimization is a natural combination to

Agenda
10:00h Technologie-Symbiose:
Topologieoptimierung & Additive Fertigung
Mirko Bromberger, Altair Engineering GmbH

10:15 Fit for AM

Mehrwert ermitteln und Implementierungshrden berwinden
Gngr Kara, EOS GmbH

10:45 Grundlegende Gestaltungsrichtlinien

fr die laseradditive Fertigung
Jannis Kranz, iLAS TUHH

11:15 Von der Topologie-Optimierung zum gedruckten Bauteil,

Materialise beschreitet neue Wege
Christophe Blanc, Materialise NV

11:45 Das grte 3D - gedruckte Teil im All Lessons Learned

Franck Mouriaux, RUAG Schweiz AG RUAG Space

12:15 Paradigmenwechsel in der Konstruktion zur Erschlieung des

vollen Potentials der additiven Fertigung
Alejandro Cervantes Herrera, Altair Engineering GmbH

12:45 Get Together