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Constructive generative design methods for qualified additive manufacturing

Abstract : Additive manufacturing (AM) technologies give more and more design freedom to designers and engi-neers to design and define highly complex geometries and material compositions. Due to a layer-by-layer processing, the constraints, methods, tools and processes of design in AM are different from that in traditional manufacturing processes. Traditional design methods and tools cannot meet the needs of design in AM. Therefore, a new re-search field, design for AM (DfAM), has emerged to serve this need. However, existing DfAM methods are either guidelines or pure computation-based, which have limited consideration of coupled constraints along the AM digital processing chain and are difficult to ensure manufactura-bility of design in AM. To obtain qualified design in AM, this research focuses on three typical existing problems in DfAM domain: Firstly, how to ensure manufacturability in (topology optimization) TO process? Secondly, how to design support structures with lightweight, easy-to-remove for post-processing and friendly heat-diffusion properties to ensure shape accuracy and improve surface roughness of printed parts? Finally, how to avoid accuracy loss in print-ing preparation of complex lattice structures and ensure their manufacturability in design?To solve the three identified problems, this research developed a set of new constructive genera-tive design methods: 1. CSG-based generative design method to ensure manufacturability in light-weight topology optimization; 2. Pattern-based constructive generative design method to optimize support structure design and 3. Toolpath-based inversed constructive design to directly ob-tain processing models of corresponding complex lattice or porous structures with qualified print-ing toolpaths. The three proposed methods can well embed AM process constraints, realize para-metric control and save computation cost in design process to obtain a set of candidate design solutions with ensured manufacturability. A set of comparison studies with existing DfAM meth-ods and a couple of experiment case studies in medical applications demonstrated the methods’ advantages. These constructive methods may have large application potential to be adopted as design and decision making tools for other industrial applications when qualified DfAM is required.
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Submitted on : Tuesday, May 17, 2022 - 2:31:27 PM
Last modification on : Saturday, June 25, 2022 - 3:53:12 AM

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  • HAL Id : tel-03670417, version 1

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Zhiping Wang. Constructive generative design methods for qualified additive manufacturing. Mechanical engineering [physics.class-ph]. École centrale de Nantes, 2021. English. ⟨NNT : 2021ECDN0034⟩. ⟨tel-03670417⟩

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