designing with inspire/materialise 3-matic for additive ... · designing with inspire/materialise...
TRANSCRIPT
Designing with Inspire/Materialise 3-matic for Additive Manufacturing
Copyright © 2014 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
Original Model
This model was previously designed and possibly optimized for traditional manufacturing techniques (ie. machining).
Material: Ti-6Al-4V
Weight: 6.203 lbs
Copyright © 2014 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
Simplify
We now create our design space by filling in all pockets and removing existing fillets. We can also use the Solid Edit tools to separate our design and non design space regions.
Remove filletsRemove holes Push/Pull to fill in gaps
Solid Edit design/non design space regions Note: Attached Video shows this process in < 1 minute.
Copyright © 2014 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
Assigning Loads/Supports
Next step is assigning loads and supports
Load Cases 5-7 are unit loads in specific
directions along global axis on back bracket
connection point
Load Cases 1-4 are unit loads in specific
directions along global axis on the front
bracket connection point
1
2
3
4
5
6
7
Copyright © 2014 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
Optimization Setup
Due to the design freedom Additive Manufacturing gives, we are not assigning any manufacturing constraints. Inspire will give us the most optimized concept given only one Shape Control, Symmetry
along the Y-Z Plane. We will Maximize Stiffness given a 30% Mass Target.
Copyright © 2014 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
Results
Results show a hollow, complex structure only manufacturable by Additive Manufacturing
Copyright © 2014 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
Traditionally with Inspire we export this result to CAD for further refinement. Since we are 3D Printing this part, we will take this result at the STL level into Materialise 3-matic for refinement.
First we Import our Inspire STL result and clean it up with the automatic fixing
tools. Auto Adjust Normals is needed here. By just using the clean up tools in Materialise 3-matic we can prepare a
printable part, but we want a smoother, cleaner, and aesthetically pleasing part.
Copyright © 2014 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
Using the sketching tools and CAD-like features in Materialise 3-matic, we manually create desirable contours based on Inspire’s results.
Copyright © 2014 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
One of the best advantages in using Materialise 3-matic is its smoothing capabilities with tessellated surfaces:
By performing a Smooth > Reduce
> Subdivide > Smooth iteration,
we now see a much cleaner,
realigned STL of the previously
tessellated surfaces
Copyright © 2014 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
Further comparison between Inspire results and refined, smoothed results from Materialise 3-matic
Copyright © 2014 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
Lastly we make slight sizing modifications to the non design space lugs to account for shrinkage in the smoothing operation
Copyright © 2014 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
Evolve Rendering Results
Results are now print ready (rendered with Evolve)
Copyright © 2014 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
Evolve Rendering Results
Copyright © 2014 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
Evolve Rendering Results
Approximate Bracket Weight: 3.553 lbs, ~ 40% Mass Savings
Copyright © 2014 solidThinking, Inc. Proprietary and Confidential. All rights reserved.
Contact:
solidThinking, Inc1820 E. Big Beaver Rd. Troy, MI 48108/ USA