CAREER: Integrated Design and Digital Fabrication using Topology Optimization and Material Extrusion 3D Printing

该学院早期职业发展（CAREER）奖支持基础研究，以制定第一个拓扑优化框架，该框架将系统地定制自由形式的计算设计，以通过特定的数字制造技术进行制造。该研究将侧重于基于材料挤出型增材制造（AM）的制造技术，该技术用于各种规模的3D打印技术。拓扑优化是一种自由形式的设计技术，可生成新的高性能设计解决方案。拓扑优化通常被认为是一种强大的面向增材制造的设计方法，因为它不需要对最终设计布局有预先设想的想法。然而，大多数拓扑优化设计必须由设计工程师进行“解释”或准备，以便于制造，这一过程可能导致最终产品的性能损失。这项研究将开发原始的拓扑优化框架，利用挤压型AM工艺提供的可能性和约束。本计画所探讨的设计与制造整合，将简化设计工程师所使用的制程，并改善最终制造产品的效能。对该项目同样重要的是综合教育计划，该计划将激励和培训下一代设计工程师在考虑制造方面的同时创造性地解决设计问题。该教育计划将激发对工程设计未来的兴趣，特别是那些通常不参与该主题的学生。该项目的总体目标是发现一种新的设计-制造模式，将设计和制造从两个独立的实体转变为一个统一的过程，消除了制造步骤的准备。这一目标将通过制定新的拓扑优化算法来实现，该算法利用与挤出型AM相关的可能性和约束。这些约束将被隐式地制定为模仿制造过程的新的制造原语。设计算法将考虑基本挤出特性和约束，包括：（i）挤出喷嘴的离散尺寸，（ii）相邻挤出件之间的粘合质量，（iii）第三维支撑，以及（iv）非稳定加工控制对挤出部分的影响。新的设计框架将针对基准问题进行验证，并将进行实验测试以调查性能。该研究具有广泛的社会影响，因为它将使许多应用在不同的领域，包括（但不限于）民用结构，航空航天和汽车零部件，体育和其他防护设备，新型轻质材料和生物医学植入物的设计。综合教育计划包括为K-12中学艺术班的学生和教师创建基于STEM的外展计划。此外，它还包括工程和计算机科学本科生以及工程研究生的课程和研究参与。该奖项反映了NSF的法定使命，并通过使用基金会的智力价值和更广泛的影响审查标准进行评估，被认为值得支持。

This Faculty Early Career Development (CAREER) award supports fundamental research to formulate the first topology optimization frameworks that will systematically tailor freeform computational design to manufacture by a specific digital fabrication technology. The research will focus on fabrication technologies based on material extrusion-type Additive Manufacturing (AM), which is used in a wide range of 3D printing technologies at various scales. Topology optimization is a freeform design technique that generates new, high-performing design solutions. Topology optimization is often suggested as a powerful design-for-AM approach because it does not require a pre-conceived idea of the final design layout. However, most topology-optimized designs must be “interpreted” or prepared by the design engineer to facilitate manufacture, a process that may result in performance loss of the final product. This research will develop original topology optimization frameworks that leverage the possibilities and constraints offered by extrusion-type AM processes. The integration of design and manufacture investigated in this project will ease the process used by design engineers and improve the performance of the final fabricated product. Equally important for the project is the integrated educational program that will inspire and train the next generations of design engineers to creatively approach design problems while considering manufacturing aspects. The educational program will stimulate interest in futures in engineering design, especially among students who do not typically engage with the topic. The overarching goal of this project is the discovery of a new design-fabrication paradigm that shifts design and manufacture from being two separate entities into a single unified process, where the preparation for fabrication step is eliminated. This objective will be achieved through the formulation of novel topology optimization algorithms that leverage the possibilities and constraints associated with extrusion-type AM. The constraints will be formulated implicitly as new manufacturing primitives that mimic the manufacturing process. The design algorithms will consider the fundamental extrusion characteristics and constraints, including: (i) discrete size of the extruding nozzle, (ii) bond quality between adjacent extrusions, (iii) support in the third dimension, and (iv) effects on the extruded sections of the unsteady processing controls. The new design frameworks will be validated against benchmark problems, and experimental testing will be performed to investigate performance. The research has broad societal impacts, as it will enable many applications in diverse fields, including (but not limited to) design of civil structures, aerospace and automotive components, sports and other protective equipment, novel lightweight materials, and biomedical implants. The integrated educational plan includes the creation of STEM-based outreach initiatives for K-12 middle school art class students and teachers. Furthermore, it encompasses courses and research engagement for undergraduate students of engineering and computer science and graduate engineering students.This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.