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计算设计，以通过特定的数字制造技术进行制造。这项研究将集中在基于材料挤压型添加剂制造(AM)的制造技术，这种制造技术用于各种规模的广泛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、高性能的设计解决方案。拓扑优化通常被认为是一种强大的面向AM的设计方法，因为它不需要预先考虑最终设计布局的想法。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，这一过程可能会导致最终产品的性能损失。这项研究将开发原创的拓扑优化框架，利用挤出型AM工艺提供的可能性和约束。本项目所研究的设计与制造一体化，将简化设计工程师的流程，提高最终产品的性能。对于该项目来说，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，创造性地处理设计问题。该教育项目将激发人们对未来工程设计的兴趣，特别是在那些通常不参与这一主题的学生中。该项目的首要目标是发现一种新的设计-制造范例，将设计和制造从两个独立的实体转变为单一的统一过程，其中消除了制造步骤的准备工作。这一目标将通过制定新的拓扑优化算法来实现，该算法利用了与挤压型AM相关的可能性和约束这些约束将被隐式地表示为模拟制造过程的新制造基元。设计算法将考虑基本的挤出特性和约束，包括：(I)挤出喷嘴的离散尺寸，(Ii)相邻挤出之间的粘结质量，(Iii)第三维支撑，以及(Iv)对非稳定加工控制的挤出截面的影响。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。这项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、航空航天和汽车部件、体育和其他保护设备、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以STEM为基础的外展活动。此外，它还包括工程和计算机科学本科生以及工程学研究生的课程和研究活动。该奖项反映了NSF的法定使命，并通过使用基金会的智力优势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.