A design method for restriction oriented lightweight design by using selective laser melting

DS 87-5 Proceedings of the 21st International Conference on Engineering Design (ICED 17) Vol 5: Design for X, Design to X, Vancouver, Canada, 21-25.08.2017

Year: 2017
Editor: Anja Maier, Stanko Škec, Harrison Kim, Michael Kokkolaras, Josef Oehmen, Georges Fadel, Filippo Salustri, Mike Van der Loos
Author: Lippert, Bastian; Lachmayer, Roland
Series: ICED
Institution: Leibniz Universität Hannover, Germany
Section: Design for X, Design to X
Page(s): 001-010
ISBN: 978-1-904670-93-3
ISSN: 2220-4342


This paper describes the implementation of internal structures for mechanically loaded components to save material, and thus for a lightweight design, by using selective laser melting. Based on the analysis of structures inspired by nature and technical analogies, a design approach for the substitution of solid geometries by internal structures is investigated. Concerning a demonstrator, a stress- and manufacturing-oriented design for the integration of internal structures is analyzed. By the consideration of design guidelines and the application of Finite Element Methods, various model generations are built up iteratively and evaluated in comparison to the initial model. For the simulation, a material database is defined to involve the anisotropic material properties. The optimized model is manufactured by using AISi10Mg powder. The deviations of the physical model from the digital model are evaluated and considered by adapting the component design according to the design approach. The final model generation enables new lightweight potentials compared to conventionally manufactured models and corresponds to the possibilities of selective laser melting.

Keywords: Additive Manufacturing, Design for Additive Manufacturing (DfAM), Design methods, Design engineering, Computer Aided Design (CAD)


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