Design Optimization for Multi Material Laser Powder Bed Fusion: Dr. Guha Manogharan: CDFAM NYC 2024

Design Optimization for Multi Material Laser Powder Bed Fusion: Dr. Guha Manogharan: CDFAM NYC 2024
cdfam.com/24-nyc/
Presentation Abstract
Additive manufacturing (AM) technology has afforded greater degree of geometrical design freedoms not otherwise available through traditional manufacturing. Multi-material laser powder bed fusion (MM-LPBF) combines the great geometric and surface roughness resolution associated with LPBF with selective powder deposition (SPD), allowing for the special tailoring of material based on functional design requirements. For instance, advanced heat exchanger design can now include copper fins for efficient heat dissipation combined with nickel alloys for structural strength, and stainless steel for corrosion resistance. The ability to selectively engineer the design and material assignment of multiple metals in true 3D voxel approach into a single component can produce extreme design advantages for both part consolidation and unnecessary material reduction. In most engineering applications (e.g. aerospace, automotive, space) weight is considered a critical design factor. Part and assembly consolidation, as well as light weighting associated with new AM technology, can now be extended beyond traditional single material design and on many length scales. To facilitate this aspiration, we have developed a framework utilizing topology optimization capable of simultaneous multi-material design, inspired by the newfound design freedoms enabled by MM-LPBF. Our motivation exists to investigate and develop new design methods which incorporate manufacturing process considerations (e.g. build orientation, minimum feature size) to produce multi-material metallic designs which meet clear objective functions, such as maximizing stiffness or thermally fluidic heat dissipation.