Print orientation and infill structure optimization for additive manufacturing

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The proposed research will investigate and contribute in the development and advancement of additive manufacturing (AM) design approaches and methodologies. The initial goal will be to exceed the capability of current algorithms and commercial software packages, later implementing them into industry applications. Three main tasks will be completed during the three-year project: (1) Infill structure optimization, (2) Print orientation optimization, and (3) Transient thermal analysis of metal AM and optimization. These tasks seek to address the major challenges associated with integrating additive manufacturing into aerospace components by developing advanced computational tools and customized numerical models based on fundamental theories. The proposed project aims to solve several challenges with using additive manufacturing such as inherent residual stresses, part distortion, and support structure issues. All three tasks involve the redesign of components or systems to solve a real-world industry challenge. Through the partnership between researchers at Queen's University (Kingston, Ontario) and industry experts at Bombardier's aerospace division (Toronto, Ontario), the project will focus on theoretical advancements and their practical application to optimization modules. The partnership will feature a three-year project with a post-doctoral fellow and three full-time graduate students.