Exploiting Advanced Manufacturing Capabilities: Topology Optimization in Design Proceedings of a Workshop (2022) / Chapter Skim
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2 Keynote Addresses
2 Keynote Addresses
Pages 6-12
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From page 6... ...
Kikuchi, 1988, Generating optimal topologies in structural design using a homogenization method, Computer Methods in Applied Mechanics and Engineering 71(2) : 197-224, https://doi.org/10.1016/0045-7825(88)
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From page 7... ...
Sigmund's team is also using current topology optimizations to design long span bridges for weight savings. While their optimized designs are not practical to build directly due to cost and manufacturability constraints, this work has provided insights on how to optimize particular elements: for example, it suggests that adding curved ribs instead of flat ones can potentially reduce the weight of the bridge girder by 30 percent, which would translate into significant reductions in the carbon footprint.
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From page 8... ...
Exploration in this design space with closed-walled structures has led r esearchers back to the previously abandoned homogenization approach to topology optimiza tion while taking advantage of advanced computer graphics and modeling tech nologies to achieve very fine resolution. This, he said, has moved the field closer to achieving theoretical values and paved the way for more accessible giga- or tera resolution topology optimization.
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From page 9... ...
As to voids in body armor materials, specifically boron carbide and aluminum silicon carbide, Sigmund noted that most commercial topology optimization software considers standard linear elasticity laws; more advanced materials models or objectives have been developed in academia but are not yet commercially available. Ned Thomas, Rice University, asked Sigmund to discuss the problems he encountered with symmetry.
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From page 10... ...
DeSimone (NAS/NAE/NAM6) , Carbon, Inc., University of North Carolina, Chapel Hill and North Carolina State University, discussed Carbon's process for rapid 3D polymer printing, current applications of this approach, and future plans for scaling up and sustainability.
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From page 11... ...
Each part is produced and inspected robotically and tracked with a digital signature that enables a product to go from design to manufacturing without losing its "digital thread." Applications and Workflow Carbon customers now manufacture a wide variety of products, including customized and stock football helmets and earbuds, with a process that can scale to manufacture hundreds of thousands of units; bike seats with improved temperature flow and reduced pressure; performance footwear for Adidas in the millions; automotive parts for Ford Motor Company and Lamborghini; dental hardware, including the first FDA-approved 3D-printed dentures; and bioabsorbable materials for surgical meshes or tissue repair. DeSimone noted that consumer products have a faster path to implementation, especially with Carbon's technology; cars, planes, and medical technology are slower to adopt new manufacturing technologies because of the regulatory approvals needed.
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From page 12... ...
As another example of the company's commitment to full-circle plastics use, Carbon has developed reversible thermosets for dental models, which enable temporary dental molds to be recycled instead of thrown out. Carbon's story demonstrates how fundamentally new, advanced technologies and materials can be effectively leveraged to create products that add value and cre ate a sustainable business model, DeSimone said.
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