3dprintconfny14

1. New Design Paradigms for
3D Printing
Krishnan Suresh
Associate Professor
Mechanical Engineering

2. CAD
SketchPad (MIT; 1963)

3. CAD: Underlying Philosophy
Influenced by traditional manufacturing
Controlled Complexity
3D Printing: Complexity is Free

4. Simple vs Complex
3D Printing
Geometric complexity is free
Controlled Complexity

5. Why Complexity?
Why design complex parts?
- Aesthetics
- Optimal
- Assembly-free
(3ders.com)
(mmsonline.com)
(bathsheba.com)

6. Optimal Design & Complexity
?
Stronger and lighter
(but more complex)
(3ders.com)

7. How to design such optimal parts?
Optimal Designs ~ Complex & Beautiful
“For the first time, our capacity to manufacture has
exceeded our capacity to design”
- Opening remark, 2013 ISAT/DARPA Workshop
Conventional CAD?

8. Example
Remove material, but keep it stiff!
A B
?

9. Visualize in 3-D

10. Idea!

11. Idea!!

12. Idea!!

13. Level Set

14. 2D Example
PareTO
Software: www.ersl.wisc.edu

15. Michell Truss
Optimal
&
Beautiful

16. Topology Optimization (3D)
60% weight 50% weight
16
6% weight

17. Hook Design
• Strong
• Lite
• Controlled complexity
Geometric complexity is free

18. New design tools
for 3d printing
will emerge

19. Simulation Questions
Conventional FEA:
Incapable!
Can I print?
Will it break?

20. Optimal Design
Design
Space
Finite Element Analysis
(FEA)
Optimal?
Change
Topology
No
100’s of iterations!
20
Conventional FEA: Incredibly slow!

21. Optimal Design
Size
Optistruct
Intel Xeon, 12
core, 92 GB
(180,60,30) 20 hours

22. New Simulation Methods
for
High Performance Computing

23. CPU vs. GPU
Cache
RAM
GPU
Memory
50~1000 GFLOP
GPUCPU
10~50
GFLOP
(1~12 cores) (100~2000 cores)

24. GPU
Off-the-shelf PCI hardware ($100 - $500)
Vendors: NVidia, ATI,

25. Trends in Computing
Computing Speed Memory Speed
Memory starved computation
Takes more time to fetch 2 numbers than to multiply
(Brodtkorb 13)

26. New simulation tools
for 3d printing
will emerge

27. Optimal Designs
PareTO
Intel i7, 8
cores, 8 GB
42 mins
Size
Optistruct
Intel Xeon, 12
core, 92 GB
(180,60,30) 20 hours
PareTO
Nvidia GTX
480, 1.5 GB
4 mins
UW-Madison

28. PareTOWorks (SolidWorks Integrated)
suresh@engr.wisc.edu

29. Real-time Design

30. Topology Optimization

31. Topology Optimization
Minimize weight within design-space subject to stress constraints
under 4 different load-conditions!

32. 450 Entries!

33. PareTO: Maximize Stiffness
Optimal design for
Maximizing Stiffness
(30% vol fraction)
Time taken: 8 mins
Laptop CPU: I7 with 480M GPU

34. PareTO: Maximize Strength
Optimal design for
Maximizing Strength
(30% vol fraction)
Time taken: 14 mins
Laptop CPU: I7 with 480M GPU
Optimal topology

35. Going beyond 3D Printing

36. Bridge Problem

37. Bridge Problem
V = 30% 1 min 10 secs

38. Airframe Seat

39. Wheel Support

40. Designing Braces for Buildings

41. Acknowledgements
Graduate Students
NSF
UW-Madison
Kulicke and Soffa
Luvata
Design Concepts
Publications available at
www.ersl.wisc.edu
suresh@engr.wisc.edu