May 30, 2017 Today little CAD interoperability with AM 4 One way - PDF document

May 30, 2017 Today little CAD interoperability with AM 4 – One way information flow HORIZON 2020 The STL‐wall Input to AM Process Planning • b‐rep type CAD only is most often a tessellation represents the shell of the (triangulation) of volume the CAD‐ • To update a CAD‐model from geometry AM Process Planning is very Computer Aided Technologies for complex • Design of support structures, Additive Manufacturing complex inner structures and anisotropic material very Tor Dokken, SINTEF Digital, Norway limited in current CAD • Support structures are tor.dokken@sintef.no today designed as part of process planning Dagstuhl seminar 17221 Geometric Modelling, Interoperability and New Challenges http://www.CAxMan.eu May 30, 2017 This project has received funding from the European Union's Horizon 2020 This project has received funding from the European Union's Horizon 2020 09/2015‐08/2018. Dagstuhl seminar 17221 Geometric Modelling research and innovation programme under grant agreement No 680448. research and innovation programme under grant agreement No 680448. Source for slide: Jan Vandenbrande, DARPA, presentation at SIAM GD, Salt Lake City, October 2015 Highlights Analysis based design (WP2) 2 5 Immediate challenges to CAx* for AM • Scale • Descriptions 2. Generation of trivariate model for • Methods analysis and multi‐ • Analysis material representations • Abstractions • Semantics 1. Automatic placement of cavities for reduced Enablers for material usage design optimization Current representations B‐rep CAD input loops cannot handle complexity of micro‐ Three main research and structure in conjunction development areas that 3. Isogeometric with a larger structure enhance the analysis‐based analysis direct on design workflow design geometry * CAx – Computer Aided Technologies May 30, 2017 May 30, 2017 This project has received funding from the European Union's Horizon 2020 This project has received funding from the European Union's Horizon 2020 Dagstuhl seminar 17221 Geometric Modelling Dagstuhl seminar 17221 Geometric Modelling research and innovation programme under grant agreement No 680448. research and innovation programme under grant agreement No 680448. CAD evolution Analysis‐based design for AM – Objectives 3 6 • To combine current CAD technologies and novel design approaches to support the Solid modelling CAD (b‐reps) CAxMan builds Isogeometric CAD (3‐variate) • Based on Ian Braids PhD (1974) • IsoGeometric Analysis (IGA) by Prof Tom shape flexibility provided by both state‐of‐the‐art and upcoming Additive Manufacturing • Describes volumes by the outer and inner Hughes (2005) technologies. • Replaces traditional shape functions in surfaces • Assumes the material is uniform throughout Finite Elements by B‐splines from CAD, • To introduce a tri‐variate shape representation built on the upcoming isogeometric the object significant increases in analysis accuracy analysis extension of the STEP standard, supporting user controlled material properties • The principle behind current state‐of‐the‐art • Opens up for 3‐variable isogeometric CAD of novel Additive Manufacturing technologies. CAD where material properties can vary • Augmented with B‐splines/NURBS in the continuously throughout the object • To integrate PDE‐based analysis into the design loop in order to optimize the shape of 1980s • Proposed as extensions to ISO 10303‐42 • CAD‐models in STEP ISO 10303 described the object and/or its physical properties. and 10303‐242 by FoF project TERRIFIC (To using b‐reps, 1990s be published in 2017 and 2018) • To introduce new interactive design techniques based on subdivision volumes , in order • B‐reps based CAD was well established • Further extensions to STEP on to fully exploit the construction of complex shapes and topologies that are enabled by before AM was born IsoGeometric CAD for AM to ISO 10303‐ • Current CAD‐system are based on ideas of Additive Manufacturing. 242 edition 3 planned by FoF project the 1970s and 1980s CAxMan in 2018 May 30, 2017 May 30, 2017 This project has received funding from the European Union's Horizon 2020 This project has received funding from the European Union's Horizon 2020 Dagstuhl seminar 17221 Geometric Modelling Dagstuhl seminar 17221 Geometric Modelling research and innovation programme under grant agreement No 680448. research and innovation programme under grant agreement No 680448.

May 30, 2017 Simplified design workflow 1. Modelling of internal structures (cavities) 7 10 The three main activities in the design workpackage are: • Main activity in "Subdivision Volumes" and "Design for Additive Manufacturing". 1. Design methods for subdivision entities targeting cavity placement Input CAD • Current implementation of automatic cavity placement based on: 2. Trivariate modelling of design geometry with B‐splines model • regular voxel grid 3. Simulation of functional properties via IGA (STEP format) • collision detection/inside‐outside computation • geometric boundary conditions (e.g. minimal wall thickness). 1. Internal structure 2. Conversion to Multiblock / 3. Isogeometric • Internal structures are exported as STEP (ISO 10303) B‐spline patches. modelling trivariate model trimmed analysis (Fraunhofer IGD) (SINTEF Digital) trivariate model (CNR‐IMATI Pavia) Cavity Preparation for structures process planning (STEP format) (meshing) Revision e.g. ‐ 18.4% WP3, WP4, WP5 and requests for material reduction WP6 processes redesign (theoretical) May 30, 2017 May 30, 2017 This project has received funding from the European Union's Horizon 2020 This project has received funding from the European Union's Horizon 2020 Dagstuhl seminar 17221 Geometric Modelling Dagstuhl seminar 17221 Geometric Modelling research and innovation programme under grant agreement No 680448. research and innovation programme under grant agreement No 680448. 1. Modelling of internal structures (cavities) 1. Modelling of internal structures (cavities) 8 11 • Main activity in "Subdivision Volumes" and "Design for Additive Manufacturing". • Main activity in "Subdivision Volumes" and "Design for Additive Manufacturing". • Current implementation of automatic cavity placement based on: • Current implementation of automatic cavity placement based on: • regular voxel grid • regular voxel grid • collision detection/inside‐outside computation • collision detection/inside‐outside computation • geometric boundary conditions (e.g. minimal wall thickness). • geometric boundary conditions (e.g. minimal wall thickness). • Internal structures are exported as STEP (ISO 10303) B‐spline patches. • Internal structures are exported as STEP (ISO 10303) B‐spline patches. Potential technological impact: • Better control for inserting topologically complex internal structures in objects at different levels of detail • Avoiding trapped powder in manufactured part Potential social/economic/competitive impact: • Less material usage/wastage • Less energy usage (both in production and operational lifetime, e.g. lighter components) Different cell configurations can be chosen May 30, 2017 May 30, 2017 This project has received funding from the European Union's Horizon 2020 This project has received funding from the European Union's Horizon 2020 Dagstuhl seminar 17221 Geometric Modelling Dagstuhl seminar 17221 Geometric Modelling research and innovation programme under grant agreement No 680448. research and innovation programme under grant agreement No 680448. 1. Modelling of internal structures (cavities) 2. Conversion from CAD to trivariate model 9 12 • Main activity in "Subdivision Volumes" and "Design for Additive Manufacturing". • Main activity in"Interoperability to CAD" and "Trivariate Shape Representation". • Current implementation of automatic cavity placement based on: • Currently working on methods for generating multiblock models where possible • regular voxel grid and trimmed models for complex cases. • collision detection/inside‐outside computation • Trivariate models support direct simulation and potential for advanced multi‐ • geometric boundary conditions (e.g. minimal wall thickness). material representations. • Internal structures are exported as STEP (ISO 10303) B‐spline patches. Pure STEP ISO 10303‐42 and multiblock application protocol for model Managed model‐based 3D Engineering (ISO 10303‐242) B‐rep CAD (SotA) Hybrid trimmed /multiblock We plan to propose this e.g. ‐ 22.3% model extension in edition 3 of material reduction ISO 10303‐242 in 2018 (theoretical) May 30, 2017 May 30, 2017 This project has received funding from the European Union's Horizon 2020 This project has received funding from the European Union's Horizon 2020 Dagstuhl seminar 17221 Geometric Modelling Dagstuhl seminar 17221 Geometric Modelling research and innovation programme under grant agreement No 680448. research and innovation programme under grant agreement No 680448.