Design for Additive Manufacturing

• Multi-Scale Topology Optimization

• Computational Mechanics & Simulation

• Implicit Function-Based Representation (FRep) 

• Finite Element Analysis (FEA)

• Additive Manufacturing & 3D Printing 

• Mathematical Modeling & Algorithm Development 

• CAD & High-Resolution Geometry Processing

• Problem-Solving & Innovation

• Interdisciplinary Collaboration 

• Analytical Thinking 

• Adaptability & Continuous Learning 

• Technical Communication

 This project developed a holistic design-through-printing framework with implicitly represented cellular materialsfor high-resolution structured materials design and manufacturing. While bio-inspired structured materials have achieved unprecedented progress in realizing exceptional, effective properties, a rational design paradigm that enables both tailoring complex three-dimensional architectures and manufacturing engineered hierarchical structured materials was still missing.

To bridge this gap, the framework utilizes a parameterized implicit function-based representation (FRep), allowing effective control over the material's microstructures to tune properties (e.g., isotropic, orthotropic, and anisotropic) while enabling functional gradation in the multi-scale hierarchical design. Given prescribed material properties in different applications, the framework finds the optimal layout of microstructures using an adaptive cluster-based topology optimization algorithm.

The geometry frustration problem caused by the mixture of distinct microstructures is simultaneously addressed through a spatial gradation scheme within the optimization loop. Lastly, the FRep-based architected material enables efficient geometry processing (e.g., slicing) for modern AM processes, thus facilitating the manufacturing of high-resolution, delicately designed materials. The proposed framework is scalable and adaptable, making it suitable for a broad spectrum of design demands across various applications.

Figure: Developed multi-scale optimization framework with implicitly represented cellular materials for high-resolution structured materials design and manufacturing

 To demonstrate the efficacy of the proposed framework, we apply it to a design problem of jet engine bracket from General Electric (GE). The design domain and boundary conditions are defined as shown in this Figure. The bracket design is formulated as an optimization problem to minimize the compliance of the entire structure subjected to a volume constraint of νf ≤ 0.09. The density of each microstructure is relaxed to vary in the full admissible range (0.3 ≤ ρe ≤ 0.8).

Figure: GE engine bracket design. a) isometric, top, and side view of engine bracket problem design domain with load and fixed support positions. b) the optimized design for the GE engine bracket, limiting the number of architected material clusters to two, F2 and F5; with a full range of relative density (0.3 ≤ ρ ≤ 0.8). c) fabricated structure using m-SLA printer and SVG files generated by STL-free slicing method presented in this work.