Machine learning and randomness in mechanical metamaterials

Conceptual design of compliant bone scaffolds by full-scale topology optimization

A promising new treatment for large and complex bone defects is to implant specifically designed and additively manufactured synthetic bone scaffolds. Optimizing the scaffold design can potentially improve bone in-growth and prevent under- and over-loading of the adjacent tissue. This study aims to optimize synthetic bone scaffolds over...

Overheating control in additive manufacturing using a 3D topology optimization method and experimental validation

Overheating is a major issue especially in metal Additive Manufacturing (AM) processes, leading to poor surface quality, lack of dimensional precision, inferior performance and/or build failures. A 3D density-based topology optimization (TO) method is presented which addresses the issue of local overheating during metal AM. This is achieved...

Design for material properties of additively manufactured metals using topology optimization

In metal Additive Manufacturing (AM), the deposited material is subjected to a series of heating and cooling cycles. The locally occurring temperature extremes and cooling rates determine solid-state phase fractions, material microstructure, texture, and ultimately the local material properties. As the shape of a part determines the local...

Poisson meets Escher: Exploring the Poisson effect in bone implant design

Since the beginning of time, humans have been trying to replace the skeletal system in cases of trauma or disease. Medical devices were designed, manufactured, and implanted, to restore the function of the skeletal system. Fast forward to today and joint replacements are among the most common surgeries carried out in the world. Despite their...

Integral Channel Nozzles and Heat Exchangers using Additive Manufacturing Directed Energy Deposition NASA HR-1 Alloy

Heat exchangers for use in propulsion applications are very critical components because they must be efficient, compact and light and often operate with working fluids at extreme temperatures or pressures or both. Various components and systems use heat exchangers such as combustion chambers of gas turbines and internal combustion engines, fuel...

Titanium alloy corrosion fatigue crack growth rates prediction: Peridynamics based numerical approach

This study presents a numerical approach for modelling the Corrosion Fatigue Crack Growth (CFCG) in conventional casting and additively manufactured Ti6Al4V alloys. The proposed numerical model, based on Peridynamics (PD), combines the PD Fatigue Crack Growth (FCG) model and PD diffusion model in order to couple the mechanical and diffusion...

Structural Design and Testing of Digitally Manufactured Concrete Structures

The form freedom enabled by digital fabrication with concrete technologies provides advantages for a wide range of concrete based objects, from architectural to structural elements. The current chapter focuses on the specifics of structural design and engineering of DFC with emphasis on those technologies based on Additive Manufacturing with...

Comparing environmental impacts of metal additive manufacturing to conventional manufacturing

Metal additive manufacturing (AM) is revered for the design freedom it brings, but is it environmentally better or worse than conventional manufacturing? Since few direct comparisons are published, this study compared AM data from life-cycle assessment literature to conventional manufacturing data from the Granta EduPack database. The...

Material Deposition in 3D Space: Additive Manufacturing Enriched by Rotational Motion

Additive manufacturing (AM) is causing a revolution in product design,<br/>manufacturing and distribution. This technology facilitates the production<br/>of complex, customized products without the need of any specific tooling,<br/>thereby enabling products to be delivered at a lower cost than with traditional<br/>manufacturing. From a design...

A Performance-Driven Approach for the Design of Cellular Geometries with Low Thermal Conductivity for Application in 3D-Printed Façade Components

Additive manufacturing allows the fabrication of complex geometries with enhanced performances, making it interesting for application in façade components. Assessing the performance of non-standard geometries and 3D printed parts requires a combination of digital and analytical methods to retrieve validated models which can guide the design...

Mechanics of Bone-substituting Meta-biomaterials

One of the main functions of bone is to support the human body mechanically. To fulfil its complex role, bone possesses unique mechanical properties: it is stiff enough to resist deformation while being able to absorb energy.<br/>In this thesis, a comprehensive study has been carried out using analytical methods, numerical methods and...

Topology optimization with overhang filter considering accessibility of supports

Convective Concrete: Additive Manufacturing to facilitate activation of thermal mass

This paper reports on the research-driven design process of an innovative thermal mass concept: Convective Concrete. The goal is to improve building energy efficiency and comfort levels by addressing some of the shortcomings of conventional building slabs with high thermal storage capacity. Such heavyweight constructions tend to have a slow...

Overhang angle control and optimal part orientation in topology optimization for additive manufacturing

Developing an Interactive Augmented Prototyping Methodology to Support Design Reviews

Physical prototypes and scale models play an important role in engineering design processes, especially in the field of industrial design. Such models are typically used to explore and discuss design concepts in various stages, from initial idea generation to manufacturing. Over the last decade, augmented reality technologies have been developed...

AM Envelope: The Potential of Additive Manufacturing for facade constructions

The continuous development of the building envelope over the past hundred years can be exemplified by a few ground-breaking inventions. Firstly, the separation of primary and secondary structure during the beginning of the 20th century; by implementing a curtain wall façade to physically separate the façade from the building. This was followed...