Holistic computational design within additive manufacturing through topology optimization combined with multiphysics multi-scale materials and process modelling

Bayat, Mohamad; Zinovieva, O.; Ferrari, Federico; Ayas, Can; Langelaar, Matthijs; Spangenberg, Jon; Salajeghe, Roozbeh; Poulios, Konstantinos; Mohanty, Sankhya; Sigmund, Ole; Hattel, Jesper Henri

doi:10.1016/j.pmatsci.2023.101129

Cited by 45 publications

(8 citation statements)

References 913 publications

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“…Figure 8 displays the SEM of 30 wt% fish scale particle‐reinforced PLA filaments, revealing clear evidence of crests and valleys in the limitations, representing the existence of voids and misdeeds on the filament surface. These observations align with similar findings reported by Mohamad Bayat et al regarding adding silicon particles to PLA polymeric filaments 39 …”

Section: Resultssupporting

confidence: 93%

“…These observations align with similar findings reported by Mohamad Bayat et al regarding adding silicon particles to PLA polymeric filaments. 39 Figure 8 presents the tensile fracture of SEM images depicting PLA/FSP biocomposites. In Figure 8a, the micrograph of neat PLA showcases a river-like pattern at the cross-section, indicative of its brittle fracture nature.…”

Section: Methodsmentioning

confidence: 99%

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Development of fish scale particle reinforced PLA filaments for 3D printing applications

Joseph Arockiam,

Rajesh,

Karthikeyan

2023

J of Applied Polymer Sci

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This study investigated incorporating fish scale powder (FSP) as a bio‐filler into polylactic acid (PLA) raw material for polymeric 3D printing. The PLA/FSP filaments were evaluated for various properties (tensile strength, tensile modulus, elongation, diameter deviation, thermogravimetric analysis, surface roughness, and SEM analysis) at different compositions (PLA, PLA/FSP10, PLA/FSP20, and PLA/FSP30 wt%). The results revealed that PLA filaments reinforced with 20 wt% FSP achieved the highest tensile strength, and modulus is 44.49 MPa and 2.83 GPa. The filaments reinforced with neat PLA and PLA with 10 wt% fish scale powder exhibited minor diameter deviations of +0.002 and −0.002. The surface roughness of the neat PLA filament is notably higher, registering a value of 1.459 μm. This finding highlights the importance of considering surface characteristics in filament selection for 3D printing applications. The microscopic analysis confirmed a uniform distribution of FSP particles in the 20 wt% composition PLA/FSP filaments. These results suggest that PLA/FSP (20 wt%) is an optimal feedstock for 3D printing, especially in developing biomaterials like bio‐scaffolds.

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Section: Resultssupporting

confidence: 93%

Section: Methodsmentioning

confidence: 99%

Development of fish scale particle reinforced PLA filaments for 3D printing applications

Joseph Arockiam,

Rajesh,

Karthikeyan

2023

J of Applied Polymer Sci

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“…It forms the foundation of integrated computational materials engineering (ICME) which aims at the optimisation of materials development. Establishing the PSPP linkage for AM materials becomes imperative in the realm of a holistic computational design approach for AM [98]. This is particularly important for new materials enabled by technology, including functionally graded materials [99][100][101], metamaterials [102,103], and bio-inspired materials [104,105].…”

Section: Process-structure-properties-performance Conceptmentioning

confidence: 99%

“…Many books on multiscale modelling discuss numerical methods and summarise models and approaches employed in PSPP and ICME to describe processes across different scales, involving from groundstate and molecular dynamics to continuum scale concepts (e.g., [110][111][112][113]). Enabling lattice structure printing, AM brought additional scale to multiscale modelling, which now separately considers a unit cell, i.e., a representation of perfectly periodic structures [98]. Homogenisation discussed in Section 1 forms the basis of multiscaling.…”

Section: Process-structure-properties-performance Conceptmentioning

confidence: 99%

A Review of Computational Approaches to the Microstructure-Informed Mechanical Modelling of Metals Produced by Powder Bed Fusion Additive Manufacturing

Zinovieva,

Romanova,

Dymnich

et al. 2023

Materials

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In the rapidly evolving field of additive manufacturing (AM), the predictability of part properties is still challenging due to the inherent multiphysics complexity of the technology. This results in time-consuming and costly experimental guess-and-check approaches for manufacturing each individual design. Through synthesising advancements in the field, this review argues that numerical modelling is instrumental in mitigating these challenges by working in tandem with experimental studies. Unique hierarchical microstructures induced by extreme AM process conditions– including melt pool patterns, grains, cellular–dendritic substructures, and precipitates—affect the final part properties. Therefore, the development of microstructure-informed mechanical models becomes vital. Our review of numerical studies explores various modelling approaches that consider the microstructural features explicitly and offers insights into multiscale stress–strain analysis across diverse materials fabricated by powder bed fusion AM. The literature indicates a growing consensus on the key role of multiscale integrated process–structure–property–performance (PSPP) modelling in capturing the complexity of AM-produced materials. Current models, though increasingly sophisticated, still tend to relate only two elements of the PSPP chain while often focusing on a single scale. This emphasises the need for integrated PSPP approaches validated by a solid experimental base. The PSPP paradigm for AM, while promising as a concept, is still in its infantry, confronting multifaceted challenges that require in-depth, multidisciplinary expertise. These challenges range from accounting for multiphysics phenomena (e.g., advanced laser–material interaction) and their interplay (thermo-mechanical and microstructural evolution for simulating Type II residual stresses), accurately defined assumptions (e.g., flat molten surface during AM or purely epitaxial solidification), and correctly estimated boundary conditions for each element of the PSPP chain up to the need to balance the model’s complexity and detalisation in terms of both multiphysics and discretisation with efficient multitrack and multilayer simulations. Efforts in bridging these gaps would not only improve predictability but also expedite the development and certification of new AM materials.

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“…Once convergence is reached during the optimization process, no further iterations will yield appreciable design improvements. (Bayat et al, 2023)…”

Section: Computational Topology Optimizationmentioning

confidence: 99%

Numerical and Experimental Photoelasticity Topology Optimization

BG,

2023

Preprint

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The photoelasticity experimental technique is developed, which extends the topology optimization method to realistic engineering design problems. The new approach enables the efficient design of complex engineering structures by allowing the designer to control the material distribution among the design areas during the optimal design process, thereby allowing the use of multiload mechanical components in a variety of applications. This study enables a novel approach to topology optimization using the photoelasticity method. The primary objective of this research is to demonstrate the viability and efficacy of using photoelasticity in topology optimization for stress-constrained design problems. The proposed methodology involves of a number of essential steps, including material selection, specimen preparation, photoelastic testing, image processing, and optimization algorithms. The integration of photoelasticity into the optimization process permits more accurate and insightful evaluations of stress distributions within structures as well as more realistic stress constraints, resulting in designs that are not only structurally efficient but also resistant to failure. The methodology presented here provides an innovative and practical approach to solving real-world engineering problems, particularly in fields where accurate stress analysis is crucial, including aerospace engineering, civil engineering, and biomechanics. The photoelasticity experimental method is demonstrated for the linking plate design problem associated with the brake drum end. The case study illustrates the potential significance of the newly developed capability for a wide variety of engineering design problems, which reduces the amount of material by 50%. This methodology expands upon conventional topology optimization techniques that rely solely on numerical simulations.

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Holistic computational design within additive manufacturing through topology optimization combined with multiphysics multi-scale materials and process modelling

Cited by 45 publications

References 913 publications

Development of fish scale particle reinforced PLA filaments for 3D printing applications

Development of fish scale particle reinforced PLA filaments for 3D printing applications

A Review of Computational Approaches to the Microstructure-Informed Mechanical Modelling of Metals Produced by Powder Bed Fusion Additive Manufacturing

Numerical and Experimental Photoelasticity Topology Optimization

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