Advances in additive manufacturing (AM) has equipped respective technologies with the capability of producing end user parts outperforming those made by conventional manufacturing. Parts have added value from a geometrical complexity and from an economic perspective at low batch production. In addition, their utilization simplifies the production process as entire components can be made in one step. The key to the success of these technologies is their tool-less operational principle allowing the direct and autonomous conversion of any complex computer-aided design (CAD) into a physical object without requiring any tooling or skilled craftsman nor involved machine set up. Together with the easy storage and handling of AM raw material, these technologies allow fabrication outside of the factory, by retailers or suppliers and ultimately by the user himself. This may lead to completely new businesses and customer designed products designed that can be fabricated on-site, in remote locations.
However, design methodologies that fully utilize the complexity obtainable with AM are yet few. Topology Optimization (TO) with the Minimum Compliance method based on Simple Isotropic Material with Penalization (SIMP) being the most commonly used. However, also in this approach, the process coming from the design stage to the final product, i.e. the process said to be accelerated by AM, is yet tedious and lengthy.
In this educational project, Master- and Bachelor Students are tackling this issue, performing simulation-based design tasks and explore the fabrication and post processing with an AM framework. Further, they are exploring the performance possibilities with those designs in real life situations, e.g. at the Formula Student Race Car competition.

Collaborators: Revolve NTNU www.revolve.no