Page 22 - 3DMP Spring 2022

3D Topology Optimization and Reusable Workflows
constant shell thickness to each subsys- tem. For example, designers could assign pneumatic inlets and outlets a greater thickness than those specified for the pneumatic channels, a process not nearly as straightforward to perform with tradi- tional CAD tools.
The last step of the process, which Blanke calls “one of the main advantages of using nTopology:” With the separate shells generated, the designs were then combined into a single body using a sim- ple boolean union. The boolean union block joins multiple implicit bodies into one with optional blending between them to add fillets.
Conformal Lattice
for Stiffness and Support
A few tasks remained, chief among them: Many interior features comprised large overhangs not conducive to metal AM, as the team sought to avoid excessive use of support structures and the tedious, wasteful process to remove them. There-
fore, the engineering team used lattice structures to provide permanent support to all interior regions of the part. Addi- tionally, the internal lattice structures increased part stiffness.
To identify the optimum lattice thick- ness, the team leveraged nTopology’s integrated simulation tools to automat- ically run multiple finite-element and lattice simulations, quickly evaluate the results and adjust specific parameters to iterate and optimize their design. The software’s integrated engineering simu- lation and design-automation capabili- ties saved Blanke’s team many engineer- ing hours, as moving to a different software would only add complexity to the workflow.
With the design complete, only a few final details needed to be added to prepare for manufacturing and post-processing. For example, any holes and hollow areas in the final model could have led to imper- fections during the AM process. So, Blanke and his team filled most of these sections
with solid material that easily could be CNC-machined afterward.
After 39 hr. of metal AM in the Lasertec 30 Dual SLM machine, and then finishing using five-axis CNC machining, the team finally had four physical prototypes of its new lightweight design ready for testing in the robotic system. Early tests showed that the new component’s higher stiff- ness-to-weight ratio helped improve the robotic system’s handling precision by a factor of 16. Now the team is planning to apply a similar methodology in nTopology to lightweight other similar components.
“The unbreakable geometry, reusable workflows, and simulation-driven design are extremely powerful ways of designing for AM,” adds Blanke.
DMG Mori expects to begin commer- cially producing the metal-AM parts by press time. 3DMP
Article provided by nTopology; www.ntopology.com.
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