Technology Symbiosis - ALM (3D printing) and Simulation Driven Design

Each of these will present their works in the area of Additive Layer Manufacturing. After the presentation session, a round table discussion will address how to leverage the full potential of resource-friendly component design by applying simulation driven design methods. In addition, the discussion will also address the commercial aspects of ALM as well as further research and development needs in this area.

“Additive manufacturing methods and 3D printing are becoming increasingly popular,” said Dr. Pietro Cervellera, Aerospace Sales Director, Altair. “Some people even say that additive methods will lead to a revolution in how the industry will manufacture products in the future, and you can definitely assume that 3D printing marks a new era in individual manufacturing, since the flexibility of this method inspires the imagination of many product designers.”

One advantage of the ALM method that often fails to gain the attention it deserves is the potential to manufacture weight and mass efficient structures without the normal constraints of traditional processes. To leverage the full lightweight potential of ALM, an optimization driven development process has to be used for the structural layout of the components.

There is often a struggle in the design process between designing an ideal shape and then manufacturing a shape economically. With ALM this can be eliminated since with this method, one can produce arbitrary shapes at similar costs.

For more than 20 years, Altair has developed OptiStruct, a tool with which completely new shapes can be discovered by leveraging topology optimization. This technology inspires lightweight design and significantly contributes to saving thousands of tons of material usage and as a result contributes to reduced CO2 emissions.

Topology optimization is the best available design method for creating requirement- and load-specific structures, and for enabling the industry to tap the full lightweight potential offered by the use of ALM structures.

From Altair’s point of view this technology is more than just a series of two technologies used one after the other. On the one hand, it is a symbiotic connection with load-specific shape definition, and on the other it’s an almost unlimited potential for production.

Altair will present and discuss this topic in detail at the 6th European Altair Technology Conference from April 22-24, 2013 at the Lingotto Conference Center in Turin.

The following presentations from technology oriented companies, users and research institutes, will address this topic and present practical examples:

• Martin Muir, EADS
Multidisciplinary Optimisation of Business Jet MED Hinge for Production by Additive Manufacturing
• Wolfgang Machunze, EADS
Topology Design of a Metallic Load Introduction Bracket Manufactured by ALM
• Vito Chinellato, EOS
Sustainability Approach by Design Optimization for Advanced Layer Manufacturing
• Simon Merkt, RWTH Aachen/ILT Fraunhofer
Digital Photonic Production - Optimization Potentials by Laser Based Manufacturing
• Jannis Kranz, TUHH
Structural Optimization and Laser Additive Manufacturing in Lightweight Design: Barriers and Chances
• Prof. Dr.-Ing. Vasily Ploshikhin, Airbus Stiftungsprofessur für Integrative Simulation und Engineering von Materialien und Prozessen (ISEMP)
Multi-Scale FEM Simulation of Selective Laser Melting Process