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

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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.