1. Prepared for By
An Company
Design Faster and Lighter: Applications of Topology Optimization in Additive Manufacturing
ATC 2015 Jaideep Bangal

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Agenda
Why?
Topology / Design Optimization – Concept Design
How?
Technology
Who?
Industry applications

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3D Printing: Changing Design and Manufacturing

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They are
cool
Elegant
design
Structural
freedom
Individual
design
Democratic
design
Complexity
is for free
Functional
integration
No tooling
Lot size 1
Custom
made parts
Spare parts
on demand
Why we look at the Additive Manufacturing?

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Why design / redesign components?
To make sure that an added value is designed into the part
• Extreme performance increase
• Lightweight parts
• Stronger parts
• Part cost reduction

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Traditional CAD systems rely on Boolean operations
“Subtractive Designing”
Traditional Design
pictures by courtesy of Laser Zentrum Nord

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“Drafting” something like this
can take weeks with a conventional system:
Efficient Design
pictures by courtesy of Laser Zentrum Nord

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What is Topology Optimization?
Topology optimization is a mathematical approach that optimizes material
layout within a given design space under given operating conditions.

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Start with original CAD design

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Create Package Space and Load Cases

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Inspire Concept Shape

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Explore Different Designs / Shapes

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Validate Inspire Concept Shape / Proposal

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Inspire Results back into CAD

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Original Design vs. Inspire Design
New Design
25%
Lighter

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3D Printing and Topology Optimization
Images courtesy of shapeways.com
3D-Printing
Form
freedom
Complexity
made easy
Individual
product
Accelerated
production
Topology
Optimization
Maximum
performance
Free-form
Individual
design
Shortened
process

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Application in Broad Industries

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Application in Broad Industries

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Design and
manufacture
based on intent
55% Mass Reduction

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21. Unlock the
lightweight
potential of AM with
concept
generation
and
organic
interpretation.
32% Weight Reduction

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Unlock the
lightweight
potential of ALM
with concept
optimization
for EADS IW
326g
918g
- 64%
“it allowed us to maximize the weight
saving benefits of the ALM process.”
Jon Meyer EADS Innovation Works

23. Unlock the
lightweight
potential of AM with
concept
optimization
and
organic interpretation
at LZN
- 26 %

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Empire Cycles World’s First 3D Printed Titanium Bike Frame

25. Spareparts made to
order, make products
live longer.
It reduces material
use and helps to
make them profitable.
Source:
“How Additive
Manufacturing Changed
the World of Engineering”
Dr.-Ing. Olaf Rehme,
Dipl.-Ing. Martin Schäfer
Siemens AG, Corporate
Technology
Material Substitution
Functionality Integration
Minimum material usage

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3D Printed Antenna Bracket for
Sentinel-1 Satellite:
• 43% weight reduction
(from 1.626 kg to 0.936 kg)
• Increased Eigen frequency
(70Hz  90 Hz)
• Improved static behaviour, strength,
stiffness, stability
From the Printer into Space

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Design
Interpretation
Geometry
creation
Evaluation
of design
Geometry
validation
From the Printer into Space
Baseline
CAD
Manufacturing 1
Image courtesy of RUAG Space
Design Process for AM

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How to …
Inspire Driven Design
unlocks the potential of
Additive Manufacturing
Explore Inspire’s
seamless
process and see
how you can benefit!
-43 %

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Question and Answers
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