REVOLUTION

IN DESIGN

- NEW APPROACHES,

PIONEERING SOLUTIONS

19 Apr 2017 | Simulation, 3D Printing I by Viktor Seres

In our recent case study, we have demonstrated that with our modern tools we are sometimes able to meet even conflicting requirements. For the sake of sustainable development, technology and product optimization with high-level coupled simulation has got a prominent role. Thanks to the developments of recent years, the appearance of the next generation of our traditional passive, command-based tools/software can radically change our daily lives. [1]

What is

the next step?

One of the greatest challenges of product development for industrial designers and mold designers is taking into account the constraints of our traditional manufacturing technology. The question is always there: can the envisioned product be manufactured properly? Should we make more simple parts or integrate multiple features within a component? Such questions arise regularly during the development process. It is vital for companies competing in fierce and ever-changing markets to find the right cost-effective solution for efficient operation. Target-oriented, generative design systems utilize the almost infinite capacity of cloud computing to offer thousands of solutions for the problem at hand based on the requirements and conditions that we create, mimicking the process of natural selection.

Finding the proper solution with optimalization

Autodesk's Dreamcatcher pilot platform, using advanced artificial intelligence, is able to process and integrate the measurement results obtained during physical tests, taking into account inputs (manufacturability, raw material, loads, cost constraints) provided during the generative design process. Using intelligent learning systems and integrated electronic tools, designers and engineers have never-before-seen optimization opportunities to identify the right solution quickly and easily. Additive manufacturing technologies play an important role in the development of generative design technologies, as the structures they create are generally not feasible with traditional manufacturing techniques. Thanks to the explosive development and democratization of 3D printing processes, we now have a wide range of raw materials and technologies that are not only suitable for prototyping, but also for finished products. With the continuous development of software, massive changes can be expected in the plastics industry over the coming years, both in product design and mold design, and mold manufacturing. 

Generative

Design

The innovation team of Under Armor, a leading American sportswear manufacturer founded in 1996, wanted to raise their training shoes to the next level on its 20th anniversary. This is how the UA Architech limited edition – available in just 96 pieces – has been created as an artistic combination of generative design and 3D printing. These high-performance shoes protect the foot during the toughest workouts, but its lightweight design makes it ideal for running as well. In addition to the many innovations, the most important element of this shoe model is the 3D printed sole, whose interwoven structure is inspired by tree roots. The geometry created with the help of Autodesk Within software has reached its final form with the active participation of 80 athletes as a result of more than two years of development work. As a result of this research, new experimental procedures and regulations have also been developed, which will be much useful in the development of similar products. [2]

Cooling and 

Load resictance in one

In the case of critical products, it has been possible for years to create efficient mold tracking coolers in the injection mold using the DMLS - Direkt Metal Laser Sintering - metal printing and advanced injection molding simulation solutions. The latest beta version of Autodesk Moldflow injection molding simulation software, market leader for more than 40 years, provides a solution to testing the fatigue of mold elements, which is a critical aspect of the design of mold tracking inserts. By combining generative design software and injection molding simulation analyses, we can have the opportunity to create an optimized mold insert design in the future that provides excellent cooling and withstands cyclic loading at the same time. 

We are at the door of a radical change. Our intelligent and constantly changing self-learning tools that communicate with each other are posing us new challenges that require a basically changed approach. It will be a priority to develop standards, test specifications and regulations that are specifically prepared to the new design and manufacturing technologies.

 

[1] The present and future of simulation by Viktor Seres – MCAD 18.05.2016

[2] Under Armour Changes the Footwear Game With Generative Design and 3D-Printed Shoes – PJ Brown – 2016