Systematic development of load-path dependent FLM-FRP lightweight structures. (22nd April 2021)

• Record Type: Journal Article
• Authors: Voelkl, Harald; Wartzack, Sandro
• Is Part Of: Design science. Volume 7(2021)
• Publication Date: 2021-04-22
• Subjects: lightweight design -- additive manufacturing -- fibre-reinforced plastics -- fused layer modelling -- structural optimisation; Design -- Research -- Periodicals; New products -- Management -- Periodicals; Design; Design -- Research; Electronic journals; Periodicals; 658.5752
• DOI: 10.1017/dsj.2021.9
• Languages: English
• ISSNs: 2053-4701

Abstract

Abstract: Additive manufacturing offers a high degree of design freedom. When Design for Additive Manufacturing is conducted properly, lightweight potential can be exploited. This contribution introduces a novel design approach for the widespread fused layer modelling (FLM) technology when using orthotropic Fibre Reinforced Polymer filament. Its objective is to obtain stiff and strong load-path optimized FLM structures in a structured and algorithmic way. The approach therefore encompasses (1) build orientation optimization to consider weaker bonding between layers than intralayer; (2) topology optimization with orthotropic material properties to obtain favourable overall geometry and inner structure; (3) direct build path generation from optimized material orientation and alternatives to the direct generation and (4) simulation. The approach is demonstrated using a lift arm under multiple load cases and further demonstrator parts to show its general applicability. Lightweight potential of individual optimization steps and the influence of modifications contrasting general non-FLM-specific optimization are studied and discussed.