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1

Using Collaborative Design and Simulation to Accelerate the Adoption of Additive

Manufacturing in Industry

白锐，达索SIMULILA亚太区战略发展总监

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2

Dassault Systèmes

An Overview of our Company and our Purpose

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3

Our Company

a ScientificcompanyCombining Science, Technology and Art for a sustainable society

13,300passionate people• 117 nationalities / 178 sites• One global R&D / 54 labs • Game changing 3DEXPERIENCE

solutions

190,000 enterprise customers• 12 industries in 140 countries• 18 million users

10,000partners• Software, Technology &

Architecture• Content & Online Services• Sales• Consulting & System

Integrators• Education• Research

Long-termdriven• Majority shareholder control • Revenue: $3.2 Bn*• Operating margin: 29.8%*

* Figures as of FY 2014 / Non-IFRS

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AMERICASHeadquartersBoston

WW & EMEAR HeadquartersParis

R&D labs (54)

3DS Offices (178)

ASIA PACIFICHeadquartersShanghai

Our Presence

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Our Clients: Industry leaders at the heart of Innovation

Aerospace & Defense

Transportation & Mobility

Marine & Offshore

High-Tech

Consumer Goods- RetailConsumer Packaged Goods- Retail

Life Sciences

Energy, Process & Utilities

Architecture, Engineering & Construction

Financial & Business Services

Industrial Equipment

Natural Resources

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7

DS Legacy

V3 V4 V5 V6

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Our 3DEXPERIENCE PLATFORM

Powersour Brands

Our 3DEXPERIENCE Platform

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9

新机器/新材料 正在改变生产方式

打印复合材料车身

金属喷镀修复

金属粉末床

并支持全新的设计方式

新材料

功能梯度材料

3D打印的内置电子线路的天线

新拓扑

钛合金带扣

新装配结构

燃油喷嘴

正在持续发展的制造业新大陆

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2014

10

增材制造 | 达索系统策略

全新的制造业务

全新的制造方式

软件服务

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“Dassault Systemes…today

announced that it has

partnered with the National

Instittue for Aviation

Research (NIAR) to open

an innovation center at

Wichita State University

(WSU) to advance the use

of new technologies such as

additive manufacturing that

will shape the future of the

aviation industry.”

Image Courtesy of Wichita State University

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“This new end-to-end

process will address

upstream material design

and downstream

manufacturing processes

and testing to provide

digital continuity for all

engineering parameters

necessary for the additive

manufacturing of an

engine part: material

science, functional

specification, generative

design, 3D printing

optimization, multi-robotic

production and

certification.”

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The new world to imagine, design and make at SAFRAN

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“Numerous projects across

Airbus are accelerating the use

of additive manufacturing to

produce prototypes as well as

production components

potentially delivering lighter and

less expensive parts that meet

technological, performance,

safety and cost standards,”

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Build/Reuse Set-up

Support Structure Generation

Laser Path Generation

Streamlined Simulation Model

Generation

Virtual 3D Print

Residual Stress and Distortion Parametric

Process Optimization

Functional Specifications

Explore Concept – Design Concept Generation

Structural Pre-Validation

Detailed Design for ALM

Detailed Design for ALM

Variants Creation and Trade-off Study (KPI)Variants Creation and Trade-off Study (KPI)

Parametric RefinementParametric Refinement

Structural ValidationStructural Validation

In-service Simulation

Printer

1. 功能驱动

的拓扑优化

设计环境

2. 增材制造

工艺仿真和

虚拟打印

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基于达索传统产品的解决方案

TOSCA: 可对增材制造的零部件进行拓扑优化设计一个满足功能需求的、轻量化的几何形状；配合

CFD软件可以进行内流道形貌优化用于增材制造

Isight: 能够驱动增材制造工艺仿真流程的参数优化分析，对打印速度、打印方向等参数进行优化

ABAQUS:高效强大的非线性求解能力能真实有效的模拟增材制造过程，预测增材工艺过程的温度

场、变形场和应力场，并可配合上述产品帮助客

户更改、优化AM增材制造方案

1. 功能驱动的拓扑优化设计环境

2. 增材制造工艺仿真和虚拟打印Parameter Definition

Geometry Update

Service load Analysis

AM Manufacturing

Simulation

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24

“3D功能性创成式设计员”的工作流指定功能规格

生成& 验证概念方案

详细建模及优化

概念性工

艺校核

1

2

3

4

定义载荷工况

&边界条件创建设计空间

&机械接口 定义目标&约束

验证比较方案& 选取概念方案

设计评审

参数优化

参数优化

校核结构

校核结构

详细设计

（面向增材制造）

详细设计

（面向减材制造）

生成设计概念预校核结构创建变异方案 探索拓扑结构

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2015

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Simulation for Additive Manufacturing

What’s the Value?

Addressing Key AM Challenges through Simulation

• Evaluate how the manufactured part will perform under realistic loading conditions in assembly with other components

In-service Performance

• Generate topology that meets functional requirements through optimization

Generate a Functional Design

• Create and optimize a lattice structure

Generate a Lattice Structure

• Develop confidence in raw and processed properties

• Capture phase transformations to understand actual performance

Calibrate the Material• Understand residual stress and

distortion• Minimize the gap between the designed

and manufactured part through process optimization

Optimize the Process

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Tosca StructureStructural optimization modules

• Topology optimization

• Modify general component layout (add and remove elements)

• Find the design with maximum stiffness or minimum weight

• Shape optimization

• Modify component surface

• Reduce local stresses and increase durability

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Optimization for Additive Manufacturing - An Example

• Design a circuit box for space shuttle application

• Costs $10,000 to put 1lb payload into Earth’s orbit

• 10s of circuit boxes in a launch vehicle and satellites

• Optimization Objectives

• Reduce mass – lightweighting

• Without significant increase in print times.

• Optimization Constraints

• Symmetric Constraint

• Frozen Area Original Design: 450 grams

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Optimization Strategy for AMCAD-Modeling and Simulation Model

Generation

CAD-Modeling and Simulation Model

Generation

Conceptual Topology Optimization for Finding of Stiff

and Lightweight Organic Structure

Conceptual Topology Optimization for Finding of Stiff

and Lightweight Organic Structure

Verification Model Generation and

Design Evaluation

Verification Model Generation and

Design Evaluation

Original Design: 450 grams

Non-Parametric / Parametric Shape

Optimization

Non-Parametric / Parametric Shape

Optimization

PrintingPrinting

CAD-Reconstruction

CAD-ReconstructionFinal Design: 315 grams

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Lattice Design

Extrude

Offset (optional)

Boolean Operations

2D motifScale, Duplicate, Join

Tessellated or exact 3D motif

Tessellated or exact 3D model

Tessellated or exact 3D Result

Tessellated or exact 3D pattern

Generate a Lattice Structure and Lattice Sizing Optimization

Upper bound

Lower bound

Radius

4 times more stiffness

40% reduction for same stiffness

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Engineering the Manufacturing Process

Closing the Gap between the “As-Designed” and the “As-Manufactured” Part

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Additive Manufacturing: One Solution, Many Processes

Technique

Powder

Bed

Binder Jetting

DirectedEnergy Deposition

MaterialExtrusion

Sheet Lamination

Photo Polymerization

Material Jetting

DescriptionThermal energy selectively fuses

regions of a powder bed.

A liquid bonding agent

is deposited to join

powder materials

A Nozzle mounted on

a multi axis arm

deposits melted

material

Material is drawn via a

nozzle, where it is

heated. It is deposited

layer by layer.

Sheets of material are

bonded to form an

object

Liquid photopolymer is

selectively cured by

light-activated

polymerization

Droplets of Build

Materials are

selectively deposited

Material Form

Powder Powder Powder or Wire “Solid” Material “Solid” Material Liquid Resin Ink

Material

• Metal

• Plastic

• Metal• Plastic• Ceramics

• Metal • Plastic• Composite

• Paper• (Metal)

• Plastic(Photopolymer -

Resin)

• Plastic

Processes Terms

Selective Laser Sintering (SLS)

Selective Laser Melting (SLM)

Electron Beam melting (EBM)

Direct Metal Laser Sintering (DMLS)

Binder Jetting (BJ)

Inkjet Powder Printing

Multi Jet Fusion (MJF)

Laser Cladding

Direct EnergyDeposition (DED)

Laser Metal Deposition (LMD)

Laser Engineered Net Shape (LENS)

Laser or Electron beam wire deposition

Fusion Deposition Modeling (FDM)

Laminated Object Manufacturing (LOM)

Paper Lamination Technology (PLT)

ultrasonic additive

manufacturing (UAM)

Stereo lithography (SLA)

Digital LightProcessing (DLP)

Photopolymer Jetting (PolyJet)

Multi Jet Modeling (MJM)

1 2 3 4 5 6 7

Consumer Applications

Professional Applications

“As-Designed” Part

The Gap between “As-Designed” and “As-Manufactured”

• Designed geometry without stresses or distortions

• Standard material property assumptions

Process Gap

• Materials• Deposition Path• Build Definition• Heat Input

• Residual Stresses• Distortions• Altered Properties

“As-Manufactured” Part

• Residual stresses built up from thermal process

• Deformations causing tolerance issues

• Material properties are a function of manufacturing process

A New Approach Will Enable Full-Scale AM with AbaqusPrint Temperature Residual Stresses

Pre-processing: Capturing the Path

SIMULIA Machine Code Neutral Format

Various machine code formats

Abaqus format input data(activation time per element)

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Comparison of Abaqus/Standard and Abaqus/Explicit

• Almost perfect linear scaling in /Explicit

• Close to linear scaling in /Standard

Performance ComparisonElements 700000

Print Time 15845 s

Std

Inc Size 300 s

Elements/Inc 13253.39

Total CPU Time 501 s

Exp

Inc Size 0.0142

Elements/Inc 0.627327

Total CPU Time 12660s

Abaqus/Standard Abaqus/Explicit

Abaqus/Standard

Abaqus/Explicit

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The Process Affects the Material• Aspects of most Additive Manufacturing processes significantly impact

the material.

• Changes in the material properties are the result of phenomena at the micro-scale that need to be captured.

• Examples:

• For composites, particles or fibers are affected by the extrusion process, impacting the directional properties of the material system

• For metals, the melting and re-solidification will produce metal phase transformations that impact stiffness and strength.

• How do we address this through simulation?

System-of-systems

Agent-based simulationFull system

Logical-Physical co-simulation

Sub-system

3D FEA, homogenous materialsComposite

3D FEA, composite materialsConstituents

3D FEA, multiple materialsMicrostructure

Phase-field simulation

Molecules

Molecular DynamicsElectrons

Chemical reaction

Material Studio:Environment for virtual screening and property prediction for a range of materials

Technology Shift: Multi-scale Modeling

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Leng

th(m

)

Time(s)10-9 10-8 10-7 10-6 10-5

10-9

10-7

10--5

10-3

10-1

TTT Phase Diagrams

10-310-4

Pure metal propertiesMechanical/Thermal

Alloy propertiesMechanical/Thermal

10-2 10-1

100

Calibrate continuum models

Homogenization

Coupon-level AMsimulation

Phase Field

BIOVIA

�� � � �� �� � � �� � ��� �

��� � � � � ����� �� � � �

HAZ Prediction

AM part simulationHeat treatmentFinal properties

Bridging the scales for Metals based Processes

Micro-Scale

Macro-Scale

Polycrystal/Phase transformation

Meso-Scale

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Process Gap

Use Parametric Optimization to Minimize the Gap

“As-Designed” Part

• Materials• Deposition Path• Build Definition• Heat Input

• Residual Stresses• Distortions• Altered Properties

Calibrated Process “As-Manufactured” Part

Process Parameter Optimization (Print Speed)• Automate the Process Modeling methodology

• Print speed is one of key process parameters-• Reduce print time with minimal residual stress and distortion.

Tem

pera

ture

Str

ess

Print Time: 15 hr Print Time: 5 hr Print Time: 2hr Print Time: 1.5hr

IDEAL

SOLUTION

Higher Stresses And Distortions

Post-Processing: Support Removal and Springback

Simulation with Supports Springback after Support Removal

Springback in Context of Support Locations

82

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Design Shape Compensation

Design

Compensation:

Given some unavoidable distortions, it’s possible to compute a “compensated” original geometry.

Modify Geometry with

Deformations

Process-in-the-loop Optimization

Path Optimization

Build Orientation

Optimization

Topology Optimization

Support Structure

Optimization

Process Simulation

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• Satellite part from China Aerospace Sci&Tech• Working with CATIA and China Innovative

Business Group• The 1st customer in China who tested and

mentioned GDE on public 3D printing conference, TCT Asia

• The customer is applying R&D budget for purchasing GDE in 2017

Mass Point(5kg)

Fix Hole

Optimization Area

China Space Academy AM design optimization in GDE

Lattice design in the zone of

relative density between 0.5 to 0.8

Initial design space Isosurface of relative

density of 0.5Isosurface of relative

density of 0.8Customer presentations on TCT Asia in

Shanghai, mentioning 3DE and DS

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Additive Manufacturing Process Simulation for the tooling with conformal cooling channel

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3D 打印叶轮

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某单位利用三维扫描叶片变形标定工艺模拟参数，然后用标定后的参

数评估预测打印效果（打印角度、打印速度等等）。

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AM printing crack vs. AM simulation results, qualitatively,

not quantitatively now

Done with old AM plugin based on tentative printing path; lacking interface with printer brands like EOS

Latest demo: Crack propagation during printing with XFEM connecting with AM modeler

China Commercial Aircraft Engine additive manufacturing centerUTRC China and Chinese mental printer vendors

Customer is investing a lot to follow up this GE successful

AM based fuel nozzle for engine

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Metal Powder Bed Process Simulation

Metal Powder Melts then Rapidly Solidifies

Distortions Result from Thermal Processes

Laser: Fast Moving and Highly Concentrated

Laser event sequence (courtesy Renishaw)

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Polymer Extrusion| Stratasys FDM

Warping Effects

Part level simulation with support structures Tool Path information from slicer

(GrabCad)

Material Orientations during layup

FDM time-lapse (Courtesy Stratasys)

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Direct Energy Deposition and Welding Processes

PolymerExtrusion “like” for material

deposition

MetalPowder

Bed “like” for moving heat

source

Moving flux modeled using Goldak distribution model

Temperature Stress

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Polymer Extrusion| Big Area Additive Manufacturing

Material: 13vol% / 20wt% Carbon Fiber reinforced ABSHigher Conductivity, stiffness in bead directionLower CTE in bead direction

Abaqus/Standard Heat Transfer Thermal Imaging Data

Experimental Data Courtesy: Oak Ridge National Laboratory, US. Dept. of Energy.

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96

Direct Energy Deposition| Ti-6Al-4V

** Denlinger, E. R., Heigel, J. C., Michaleris, P., & Palmer, T. A. (2015). Journal of

Materials Processing Technology, 215, 123-131.

Mechanical Deflections: Abaqus Static Analysis correlation with experiments**

Dashed: Measured

Solid: Simulated

Dashed: Measured

Solid: Simulated

Thermal History: Abaqus Thermal Analysis correlation with experiments**

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Seminars in Shanghai

98

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Public training in Beijing

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1. Create a Functional Generative Design

4. Design Material by Process Type

2. Guide the Manufacturing Process

3. Assess Print Quality andReliability

Closing the gap between the ‘as-designed’ part and the ‘as-

manufactured’ part

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100