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Additive Manufacturing (AM) offers advantages over conventional manufacturing processes, particularly by reducing the number of parts produced through multistage combined technologies, but these often result in low manufacturing yields or require post-processing. AM facilitates the production of complex geometries with fine features, overhangs, and lattice structures. For instance, Laser Powder Bed Fusion (LPBF) technology enables the fabrication of intricate parts that can be easily post-processed by removing residual powder. Laser powder bed AM technologies are widely discussed in the literature due to their design freedom in creating complex geometries, with and without the need for support generation. However, rapid solidification due to a thermal gradient in the build direction, which leads to the formation of columnar grains and warpage, is one of the challenges. To address this challenge, we propose layer-by-layer metal FFF technology, followed by the debinding and sintering process, as an alternative to powder- and laser-based approaches. Furthermore, design for additive manufacturing (DfAM) principles are discussed to minimize the need for support generation and enable easy post-processing, thereby improving surface finish to meet high tolerances in fabricating components for aerospace and healthcare applications.
Lestofire is an academic software for the automated design of engineering components. It finds the optimal geometry of a system to minimize a given cost function while constrained by a given set of physics equations. Using a level set function to describe the geometry, lestofire uses shapes derivative to evolve the system until its optimal shape. It leverages the compilation of variational forms in Firedrake (https://www.firedrakeproject.org/) and the automated calculation of shape derivatives via pyadjoint (http://www.dolfin-adjoint.or/en/latest/) to allow fast prototyping of different physics, cost functions and design parametrizations.
The purpose of this project was to devise, implement, and demonstrate a method that can use Sandia's existing analysis codes (e.g., Sierra, Alegra, the CTH hydro code) with minimal modification to generate objective function gradients for optimization-based design in transient, non-linear, coupled-physics applications. The approach uses a Moving Least Squares representation of the geometry to substantially reduce the number of geometric degrees of freedom. A Multiple-Program Multiple-Data computing model is then used to compute objective gradients via finite differencing. Details of the formulation and implementation are provided, and example applications are presented that show effectiveness and scalability of the approach.
The purpose of this CRADA was to integrate a reduced order model simulation capability into advanced engineering design capabilities. This work contributed to a substantial reduction in the time required to simulate an additive manufacturing process. Shorter simulation time improves the commercial viability and practical utility of the Sunata software and may lead to wider adoption of additive manufacturing processes.
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