Multiscale Design and 3D printing of Ultralight Hierarchical Cellular Materials: Durability of Multi-Jet and FDM Prototypes

NOVACAD Systems是一家位于加拿大的增材制造和后处理公司，利用不断增长的精确增材制造组合来制造由塑料，尼龙和聚合物制成的耐用和高精度产品。考虑到对结构耐久性和工程部件轻量化的关注，NOVACAD正在寻找开发系统的策略，在不影响其机械功能的情况下减轻结构和建筑部件的重量。受优化的轻质天然材料的启发，这种材料具有独特的多相分层微观结构，分层蜂窝材料是一种很有前途的解决方案，可用于开发具有高抗压强度的轻质和耐损伤结构元件。NOVACAD关注的是由多喷射打印（MJP）、彩色喷射打印（CJP）和熔融沉积建模（FDM） 3D打印机增材制造的轻质分层蜂窝材料的结构耐久性和制造缺陷。因此，本研究的目的是评估（数值和实验）由自由形式多层次结构制成的3D打印超轻聚合物细胞材料的结构耐久性、可重构性和可制造性。本项目旨在优化蜂窝材料的制造工艺和材料结构，开发高效、无缺陷的多功能轻量化工程部件。考虑到增材制造服务的全球价值从2015年的40亿美元增长到2021年的108亿美元，该项目使NOVACAD能够优化其3D打印技术，以制造结构耐用的超轻材料，同时为麦吉尔团队提供了一个独特的机会，将他们在先进细胞超材料的计算力学和多物理场模拟方面的专业知识应用于开发强大的设计，模拟，增材制造和先进材料的表征。转让给NOVACAD的技术将增加公司的市场规模**，使加拿大保持在先进材料设计和增材制造的前沿。

NOVACAD Systems is an additive manufacturing and post-processing company in Canada utilizing a growing**portfolio of precise additive manufacturing to fabricate durable and highly-accurate products made of plastics,**nylons, and polymers. Considering the concerns over the structural durability and lightweighting of engineering**components, NOVACAD are looking for developing systematic strategies to reduce the weight of structural**and architectural components without compromising their mechanical functionalities. Inspired by optimized**lightweight natural materials, which show unique hierarchical microstructures with multiple phases,**hierarchical cellular materials are a promising solution for developing lightweight and damage tolerant**structural elements with high compressive strength capabilities. NOVACAD is concerned about the structural**durability and manufacturing defects of lightweight hierarchical cellular materials additively manufactured by**Multi-Jet Printing (MJP), Color-Jet Printing (CJP), and Fused Deposition Modeling (FDM) 3D printers. As a**result, the objectives of this research are to evaluate (numerically and experimentally) the structural durability,**reconfigurability, and manufacturability of 3D printed ultralight polymeric cellular materials made of free-form**multi-level architectures. The project aims at optimizing the manufacturing process and material architecture of**cellular materials to develop highly-efficient and defect-free multifunctional lightweight engineering**components. Considering the magnificent growth in the global value of additive manufacturing services from**$4 billion in 2015 to $10.8 billion in 2021, the project allows NOVACAD to optimize their 3D printing**technology to manufacture structurally durable ultralight materials, while providing a unique opportunity to**McGill team to apply their expertise on computational mechanics and multiphysics simulation of advanced**cellular metamaterials for developing robust methodologies for design, simulation, additive manufacturing, and**characterization of advanced materials. The transferred technology to NOVACAD will increase the market size**of the company, keeping Canada at the forefront of design and additive manufacturing of advanced materials.