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

这个小企业创新研究（SBIR）第一阶段项目通过自动化设计软件加速了最终用途零件增材制造的发展。增材制造已经成为传统减法制造的一种有吸引力的替代方案，可以制造具有定制刚度和强度的最终用途部件。为最终用途部件释放增材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高的工程设计时间。这项新技术将使当前缓慢、繁琐、容易出错的设计过程转变为自动化设计过程。该算法利用高性能计算，并根据强度、特定材料特性和制造限制来设计组件。该技术有望减少工程设计时间，从而减少生产成本和时间，从而使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，并且可以制造轻质结构。重量的减轻导致航空和汽车工业的燃料消耗减少，这将提供生态和经济效益。这个小型企业创新研究（SBIR）第一阶段项目通过(a)开发优化布局、纤维路径和塑料填充分布的新方法，(b)基于结构性能和效率生成增材制造工具路径，以及(c)实施多种失效标准以了解复合材料增材制造中的失效载荷，从而推进了最先进的技术。由于连续纤维长丝和塑料填充物的成本差异很大，因此考虑纤维路径、碳纤维增强区域和塑料填充物布局的设计至关重要。另一个挑战是，目前的设计过程不包括一个单一的失效准则，可以预测在不同的加载情况下的失效。为了解决这两个挑战，该团队正在研究一种基于刚度和强度的复合材料增材制造拓扑优化，从而能够同时设计3D打印的几何布局和工具路径。材料在不同方向上的刚度和强度的各向异性被实现，以充分利用复合材料部件的潜力。刀具路径约束，如曲率，最小长度和宽度也在优化过程中实现，以防止打印失败。最后，将开发智能切片程序来控制3D打印机喷嘴的运动，消除由于应力集中而导致的零件故障。该奖项反映了美国国家科学基金会的法定使命，并通过使用基金会的知识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 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.