More Stiffness with Less Fiber: End-to-End Fiber Path Optimization for 3D-Printed Composites
More Stiffness with Less Fiber: End-to-End Fiber Path Optimization for 3D-Printed Composites
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DOI：
10.1145/3623263.3623356
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发表时间：
2022-05
期刊：
影响因子：
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通讯作者：
Xingyuan Sun;Geoffrey Roeder;Tianju Xue;Ryan P. Adams;S. Rusinkiewicz
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作者：
Xingyuan Sun;Geoffrey Roeder;Tianju Xue;Ryan P. Adams;S. Rusinkiewicz
在3D打印中，刚性纤维（例如碳纤维）可以增强具有有限刚度的热塑性聚合物。然而，现有的商业数字制造软件仅提供了几种简单的光纤布局算法，这些算法仅使用形状的几何形状。在这项工作中，我们建立了一个自动光纤路径规划算法，该算法可以在给定的外部负载下最大化3D打印的刚度。我们将其形式化为一个优化问题：设计一个目标函数来测量物体的刚度，同时正则化纤维路径的某些特性（例如，平滑度）。为了初始化每条纤维路径，我们使用有限元分析来计算物体上的应力场，并沿着应力场的方向贪婪地“行走”。然后，我们应用了一种基于梯度的优化算法，该算法使用伴随方法来计算相对于纤维布局的刚度梯度。在仿真和现实世界的实验中，我们将我们的方法与三个基线进行了比较：(1)由Markforged开发的领先数字制造软件包Eiger生成的同心圆光纤环，(2)对模拟应力场进行贪婪提取（即我们的方法未进行优化），以及(3)对通过平滑模拟应力场计算的光纤方向场进行贪婪算法。结果表明，使用本算法生成的纤维路径的目标在使用较少纤维的情况下获得了更高的刚度，该算法改进了目标刚度的Pareto边界作为纤维使用的函数。烧蚀研究表明，为了实现可行的光纤路径和优化的稳定性，需要平滑正则化器，与单分辨率优化相比，多分辨率优化有助于减少运行时间。
In 3D printing, stiff fibers (e.g., carbon fiber) can reinforce thermoplastic polymers with limited stiffness. However, existing commercial digital manufacturing software only provides a few simple fiber layout algorithms, which solely use the geometry of the shape. In this work, we build an automated fiber path planning algorithm that maximizes the stiffness of a 3D print given specified external loads. We formalize this as an optimization problem: an objective function is designed to measure the stiffness of the object while regularizing certain properties of fiber paths (e.g., smoothness). To initialize each fiber path, we use finite element analysis to calculate the stress field on the object and greedily “walk” in the direction of the stress field. We then apply a gradient-based optimization algorithm that uses the adjoint method to calculate the gradient of stiffness with respect to fiber layout. We compare our approach, in both simulation and real-world experiments, to three baselines: (1) concentric fiber rings generated by Eiger, a leading digital manufacturing software package developed by Markforged, (2) greedy extraction on the simulated stress field (i.e., our method without optimization), and (3) the greedy algorithm on a fiber orientation field calculated by smoothing the simulated stress fields. The results show that objects with fiber paths generated by our algorithm achieve greater stiffness while using less fiber than the baselines—our algorithm improves the Pareto frontier of object stiffness as a function of fiber usage. Ablation studies show that the smoothing regularizer is needed for feasible fiber paths and stability of optimization, and multi-resolution optimization helps reduce the running time compared to single-resolution optimization.