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Topology optimization for AM

Team A: The Promotion - Part I | A PAM2 mini-series

Part I of this mini-series introduces the initial problem, which will be solved step by step throughout the whole series. The tasks are to design a new bridge over a river with fixed boundary conditions and to prototype a scale model of it. In this short clip, topology optimization is used to draft a first simple 2D sketch of the bridge, which will be further improved during the series and later on 3D printed with the AM-SLM process. Thus, the optimization algorithm is extended to avoid overhang structures, which are one common issue in 3D printing. The movie explains general problems and basic concepts, which need to be kept in mind during the development of new additively manufactured parts. Moreover, a short insight into the daily lives of employees and research staff is shown in a satiric and fictional way.

Team B: µ-intro to AM – Episode 1: Introduction to Topology Optimization for Additive Manufacturing

This is the first episode of a series of mini-movies about some of the topics concerning Additive Manufacturing, ranging from design and modelling of the part to its manufacturing, post-processing and measurement. This first episode gives a 3-minute-long introduction to Topology Optimization for Additive Manufacturing.

Team C: Lecture 1: Design with Maths for 3D Printing

This video is the first lecture on 3D Printing in which we will go through the design process using mathematics. Watch the video to learn more about it, and share it!

Modelling of AM

Team A: The Promotion - Part II | Modelling of Additive Manufacturing

Let us introduce a new character: The Client! Will he get in the way between Markus and his promotion? At PAM2 headquarters a new challenge is overwhelming its employees: The Client’s desire for a complete computational analysis of the bridge before prototyping fosters competition between coworkers. The selected prototyping process, Selective Laser Melting or SLM, is surely complex since it involves dynamical phenomena driven by a time dependent temperature gradient: applying a numerical method to create precise models of the consolidation process would help the development of the SLM technique, if validated against the experiment, and therefore speed up the process itself as it wouldn’t anymore rely on the sole user AM experience or trial-and-error. Is PAM2 experienced enough to tackle this new problem? Will Markus stand out again to pursue his promotion? Watch it to answer those questions! And follow this channel for Part III ! PS: as always, the daily lives of employees and research staff is shown in a satiric and fictional way.

Team B: µ-intro to AM – Episode 2: Introduction to Process Simulation of Additive Manufacturing

This is the first episode of a series of mini-movies about some of the topics concerning Additive Manufacturing, ranging from design and modelling of the part to its manufacturing, post-processing and measurement. This first episode gives a 3-minute-long introduction to Topology Optimization for Additive Manufacturing.

Team C: Lecture 2: Process Modeling

In this second lecture we will focus on the computer modelling for 3D printing and its advantages. Watch the video to learn more about it, and share it!

AM process and post-processing

Team A: The Promotion - Part III | Additive Manufacturing processing and post-processing

It is finally time for manufacturing! The bridge prototype is ready for SLM production, and our PAM² employees are working days and nights to deliver as fast as humanly possible. CAD files are being sliced, manufacturability assessments are being performed, and trainings on state of the art post-processing equipment are being followed. Will this be enough for a promotion? Meet again our team on their AM journey, and learn with us about Additive Manufacturing processes, as well as laser-polishing post-processes! Laser polishing is a technique by which the surface roughness of parts can be reduced avoiding conventional grinding and polishing. In laser-polishing the laser spot irradiates the sample surface with short laser pulses at a power density that causes surface remelting and consequently smoothening due to interfacial tension. The aim is to deliver the shiniest of the bridges to The Client! Enjoy the new episode and follow this channel for the series Grand Finale ! PS: as always, the daily lives of employees and research staff is shown in a satiric and fictional way.

Team B: µ-intro to AM – Episode 3: Introduction to Processing, Metrology and post-processing for AM

This is the third and last episode of a series of mini-movies about the entire chain of additive manufacturing, ranging from design and modelling of the part to its manufacturing, post-processing and measurement. This episode gives a 4-minute-long insight into the basics of the AM processing, post-processing and surface measurement.

Team C: Lecture 3: AM processes and post-processing

In this third lecture we will focus on the production and post processing steps to obtain a high quality part. Watch the video to learn more about it, and share!

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