SBIR Phase I: Computational Synthesis of 3D Printed Composite and Infill Layouts

这个小型企业创新研究(SBIR)第一阶段项目通过自动化设计软件加速了最终用途部件的添加制造的增长。加法制造已经成为传统减法制造的一种有吸引力的替代方案，用于制造具有定制刚度和强度的最终用途部件。释放终端零件附加制造潜力所需的关键生产阶段是设计过程，目前需要丰富的工程经验和较长的工程设计时间。这项新技术将允许从目前缓慢、乏味和容易失败的设计过程向自动化设计过程的范式转变。该算法利用高性能计算，并根据强度、特定材料特性和制造约束来设计零部件。这项技术预计将减少工程设计时间，从而减少生产成本和时间，从而使该行业能够规模化生产。此外，通过使用自动化设计过程，可以定制材料分布以实现所需的结构响应，并可以制造出轻量化的结构。这个小型企业创新研究(SBIR)第一阶段项目通过(A)开发新的方法来优化布局、纤维路径和塑料填充分布，(B)基于结构性能和效率生成附加制造刀具路径，以及(C)实施多个失效标准来了解复合添加剂制造中的失效载荷，从而推动了最新技术的发展。由于连续纤维长丝和塑料填充物的成本差异很大，因此需要考虑纤维路径、碳纤维增强区域和塑料填充物布局的设计。另一个挑战是，目前的设计过程没有包括单一的失效标准，可以预测不同加载情况下的失效。为了应对这两个挑战，该团队正在研究一种基于刚度和强度的复合添加剂制造的拓扑优化方法，该方法将能够同时设计3D打印的几何布局和刀具路径。为了充分利用复合材料部件的潜力，实现了不同方向上各向异性材料的刚度和强度特性。优化过程中还实施了曲率、最小长度和宽度等刀具路径约束，以防止打印失败。最后，将开发一个智能切片程序来控制3D打印机喷嘴的运动，并消除由于应力集中而导致的部件故障。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 Small Business Innovation Research (SBIR) Phase I project expedites the growth of additive manufacturing for end-use parts through automated design software. Additive manufacturing has emerged as an appealing alternative to traditional subtractive manufacturing to fabricate end-use parts with tailored stiffness and strength. A critical production stage required to unlock the potential of additive manufacturing for end-use parts is the design process, which currently requires extensive engineering experience and high engineering design time. The new technology will allow a paradigm shift from the current slow, tedious, and failure-prone design process to an automated design process. The algorithm utilizes high-performance computing and designs components based on strength, specific material properties, and manufacturing constraints. The technology is expected to reduce engineering design time and, as a result, the production cost and time, which will enable the industry to scale production. Additionally, by using the automated design process, the material distribution can be tailored to achieve the desired structural responses, and lightweight structures can be fabricated. The reduction in weight results in a reduction in fuel consumption in aviation and auto industries, which will provide both ecological and economic benefits.This Small Business Innovation Research (SBIR) Phase I project advances the state of the art by (a) developing novel approaches to optimize layout, fiber paths, and plastic infill distribution, (b) generating additive manufacturing toolpaths based on structural performance and efficiency, and (c) implementing multiple failure criteria to understand failure loads in composite additive manufacturing. Due to the significant cost difference between continuous fiber filament and plastic infill, it is crucial to consider the design of fiber paths, carbon fiber reinforced regions, and plastic infill layout. Another challenge is that current design processes do not include a single failure criterion that can predict failure under different loading scenarios. To address these two challenges, the team is investigating a stiffness and strength-based topology optimization for composite additive manufacturing that will enable the design of the geometric layout and toolpath for 3D printing simultaneously. Anisotropic material properties for stiffness and strength in different directions are implemented to utilize the full potential of composite parts. Toolpath constraints such as curvature, minimum length, and width are also implemented in the optimization process to prevent print failure. Finally, an intelligent slicing program will be developed to control the movement of the 3D printer nozzle and eliminate part failure due to stress concentration.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.