I-Corps: Computational Synthesis of 3D Printed Composite Lattice Structures

这个I-Corps项目更广泛的影响/商业潜力是开发一个集成软件，用于几何建模，设计优化，模拟和生成复合材料网格结构的3D打印输入。使用所提出的软件技术，将设计出更坚固的部件，复合材料增材制造（AM）部件的分析将自动化，各种设计的制造将更加高效。所提出的技术的初步结果表明，它有可能设计先进的复合材料结构的概念，是一个数量级的刚度比国家的最先进的层压复合材料具有相同的重量。集成的软件将促进纤维增强聚合物3D打印在各个领域的普遍采用，例如医疗，航空航天，汽车和能源领域，这些领域可以从高性能复合材料中受益。优化的复合材料AM可用于各种应用，其中一些是工具、模制、主要和次要承载结构以及高速率、大批量制造。通过解决关键的设计和分析问题，集成软件技术将有助于复合材料AM从目前的15亿美元增长到2028年预测的90亿美元。这个I-Corps项目是基于多尺度设计优化的发展，通过利用数值均匀化获得的晶格的有效属性。由于空间谐波的使用，具有不同各向异性程度的各种类型的晶格的构造、基于均匀化的优化和投影是可能的。已发表的拟议框架的实验验证结果表明，优化的增材制造（AM）复合材料设计比当前的复合材料结构刚度高100%，强度高50%。该项目包括以下新功能：1）在3D打印复合材料层压板中组合连续纤维路径和铺层布局设计优化; 2）构建连贯的形状保持方向以建立互连的微观结构;以及3）在设计过程中纳入打印纤维和打印分辨率约束。具有任意纤维图案的复合材料晶格结构可能难以建模，因为纤维角度从元件到元件变化。因此，提出的自动化建模框架的开发是为了创建一个3D打印的纤维聚合物和接口与有限元分析，以执行和返回的重量，位移，应力和局部故障。这个奖项反映了NSF的法定使命，并已被认为是值得通过评估使用基金会的智力价值和更广泛的影响审查标准的支持。

The broader impact/commercial potential of this I-Corps project is the development of an integrated software for geometrical modeling, design optimization, simulation, and the generation of 3D printing input for composite lattice structures. Using the proposed software technology stronger parts will be designed, the analysis of composite additively manufactured (AM) parts will be automated, and the fabrication of various designs will be more efficient. The preliminary results of the proposed technology suggest that it has the potential to design advanced composite structural concepts that are an order of magnitude stiffer than the state-of-the-art laminate composites with the same weight. The integrated software will prompt the ubiquitous adoption of the 3D printing of fiber reinforced polymers in various sectors, such as the medical, aerospace, automotive, and energy sectors, which can benefit from the high-performance composites. The optimized composite AM may be utilized for a variety of applications, some of which are tooling, molding, primary and secondary load-bearing structures, and high-rate, large-volume manufacturing. By addressing the critical design and analysis issues, the integrated software technology will contribute to the growth of composite AM from the current level of 1.5 billion USD to the predicted 9 billion USD in 2028.This I-Corps project is based on the development of multiscale design optimization by utilizing the effective properties of lattices obtained by numerical homogenization. Due to the use of spatial harmonics, the construction, homogenization-based optimization, and projection of various types of lattices with different degrees of anisotropy are possible. The published experimentally validated results of proposed framework demonstrated that the optimized additively manufactured (AM) composite designs are 100% stiffer and 50% stronger than current composite structures. This project includes the following new features: 1) combined continuous fiber paths and ply layout design optimization in 3D printed composite laminates; 2) constructing a coherent shape-preserving orientation to establish an interconnected microstructure; and 3) incorporating printed fiber and printing resolution constraints in the design process. Composites lattice structures with arbitrary fiber patterns can be difficult to model because the fiber angle varies from element to element. Thus, the proposed automated modeling framework is developed to create a 3D printed fiber polymer and interfaces with finite element analysis to perform and return the weight, displacements, stresses, and local failures.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.