Challenges and Status on Design and Computation for Emerging Additive Manufacturing Technologies

Yuen-Shan Leung1, Tsz-Ho Kwok2, Xiangjia Li1, Yang Yang1, Charlie C. L. Wang3, Yong Chen1
1Epstein Department of Industrial and Systems Engineering, University of Southern California, Los Angeles, CA 90089
2Department of Mechanical, Industrial and Aerospace Engineering, Concordia University, Montreal, QC H3G 1M8, Canada
3Department of Mechanical and Automation Engineering, The Chinese University of Hong Kong, Shatin, Hong Kong, China

Tóm tắt

The revolution of additive manufacturing (AM) has led to many opportunities in fabricating complex and novel products. The increase of printable materials and the emergence of novel fabrication processes continuously expand the possibility of engineering systems in which product components are no longer limited to be single material, single scale, or single function. In fact, a paradigm shift is taking place in industry from geometry-centered usage to supporting functional demands. Consequently, engineers are expected to resolve a wide range of complex and difficult problems related to functional design. Although a higher degree of design freedom beyond geometry has been enabled by AM, there are only very few computational design approaches in this new AM-enabled domain to design objects with tailored properties and functions. The objectives of this review paper are to provide an overview of recent additive manufacturing developments and current computer-aided design methodologies that can be applied to multimaterial, multiscale, multiform, and multifunctional AM technologies. The difficulties encountered in the computational design approaches are summarized and the future development needs are emphasized. In the paper, some present applications and future trends related to additive manufacturing technologies are also discussed.

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2010, Multiscale Heterogeneous Modeling With Surfacelets, Comput.-Aided Des. Appl., 7, 759, 10.3722/cadaps.2010.759-776

2017, A Multiscale Materials Modeling Method With Seamless Zooming Capability Based on Surfacelets, ASME J. Comput. Inf. Sci. Eng., 17, 021007, 10.1115/1.4034999

2014, Inverse Surfacelet Transform for Image Reconstruction With Constrained-Conjugate Gradient Methods, ASME J. Comput. Inf. Sci. Eng., 14, 021005, 10.1115/1.4026376

2011, Formulation and Calibration of Higher-Order Elastic Localization Relationships Using the MKS Approach, Acta Mater., 59, 4595, 10.1016/j.actamat.2011.04.005

2011, Three-Phase Solid Oxide Fuel Cell Anode Microstructure Realization Using Two-Point Correlation Functions, Acta Mater., 59, 30, 10.1016/j.actamat.2010.08.012

2012, New Approximate Solution for N-Point Correlation Functions for Heterogeneous Materials, J. Mech. Phys. Solids, 60, 104, 10.1016/j.jmps.2011.09.009

2014, Descriptor-Based Methodology for Statistical Characterization and 3D Reconstruction of Microstructural Materials, Comput. Mater. Sci., 85, 206, 10.1016/j.commatsci.2013.12.046

2015, Structure–Property Linkages Using a Data Science Approach: Application to a Non-Metallic Inclusion/Steel Composite System, Acta Mater., 91, 239, 10.1016/j.actamat.2015.02.045

2015, Generalized Periodic Surface Model and Its Application in Designing Fibrous Porous Media, Eng. Comput., 32, 7, 10.1108/EC-03-2013-0085

2013, Digital Grotesque

2017, Topology Optimization for Heat Conduction Using Generative Design Algorithms, Struct. Multidisp. Optim., 55, 1063, 10.1007/s00158-016-1563-6

2017, Single-Loop Foldable 8R Mechanisms With Multiple Modes, New Trends in Mechanism and Machine Science, 503

Rhoads, B. P., and Su, H.-J., 2016, “The Design and Fabrication of a Deformable Origami Wheel,” ASME Paper No. DETC2016-60045.10.1115/DETC2016-60045

2002, Modelling the Folding of Paper Into Three Dimensions Using Affine Transformations, Linear Algebra Appl., 348, 273, 10.1016/S0024-3795(01)00608-5

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2010, Freeform Rigid-Foldable Structure Using Bidirectionally Flat-Foldable Planar Quadrilateral Mesh, Advances in Architectural Geometry, 87

2013, Soft Folding, Comput. Graph. Forum, 32, 167, 10.1111/cgf.12224

2016, An Approach to Designing Origami-Adapted Aerospace Mechanisms, ASME J. Mech. Des., 138, 052301, 10.1115/1.4032973

2008, Curved Folding

2017, String Actuated Curved Folded Surfaces, ACM Trans. Graph., 36, 10.1145/3015460

2008, Towards Flattenable Mesh Surfaces, Comput.-Aided Des., 40, 109, 10.1016/j.cad.2007.06.001

Fang, G., Matte, C.-D., Kwok, T.-H., and Wang, C. C. L., 2018, “Geometry-Based Direct Simulation for Multi-Material Soft Robots,” IEEE International Conference on Robotics and Automation (ICRA), Brisbane, Australia, May 21–25.10.1109/ICRA.2018.8461088

2017, A Soft Total Artificial Heart—First Concept Evaluation on a Hybrid Mock Circulation, Artif. Organs, 41, 948, 10.1111/aor.12956

2015, Design, Fabrication and Control of Soft Robots, Nature, 521, 467, 10.1038/nature14543

2017, Automatic Design of Fiber-Reinforced Soft Actuators for Trajectory Matching, Proc. Natl. Acad. Sci., 114, 51, 10.1073/pnas.1615140114

2007, Robust and Efficient Estimation of Elasticity Parameters Using the Linear Finite Element Method, Simulation Und Visualisierung

2009, Capture and Modeling of Non-Linear Heterogeneous Soft Tissue, ACM Trans. Graph., 28, 89, 10.1145/1576246.1531395

2015, Interactive Material Design Using Model Reduction, ACM Trans. Graph., 34, 18, 10.1145/2699648

2016, Data-Driven Bending Elasticity Design by Shell Thickness, Comput. Graph. Forum, 35, 157, 10.1111/cgf.12972

2013, Computational Design of Actuated Deformable Characters, ACM Trans. Graph., 32, 82, 10.1145/2461912.2461979

2009, Numerical Coarsening of Inhomogeneous Elastic Materials, ACM Trans. Graph., 28, 51:1, 10.1145/1531326.1531357

2015, Data-Driven Finite Elements for Geometry and Material Design, ACM Trans. Graph., 34, 74:1, 10.1145/2766889

2016, High-Force Soft Printable Pneumatics for Soft Robotic Applications, Soft Rob., 3, 144, 10.1089/soro.2016.0030

2014, Dynamic Simulation of Soft Multimaterial 3D-Printed Objects, Soft Rob., 1, 88, 10.1089/soro.2013.0010

Cheney, N., MacCurdy, R., Clune, J., and Lipson, H., 2013, “Unshackling Evolution: Evolving Soft Robots With Multiple Materials and a Powerful Generative Encoding,” 15th Annual Conference on Genetic and Evolutionary Computation, Amsterdam, The Netherlands, July 6–10, pp. 167–174.

2012, SOFA: A Multi-Model Framework for Interactive Physical Simulation, Soft Tissue Biomechanical Modeling for Computer Assisted Surgery, 283

Duriez, C., 2013, “Control of Elastic Soft Robots Based on Real-Time Finite Element Method,” IEEE International Conference on Robotics and Automation (ICRA), Karlsruhe, Germany, May 6–10.10.1109/ICRA.2013.6631138

Largilliere, F., Verona, V., Coevoet, E., Sanz-Lopez, M., Dequidt, J., and Duriez, C., 2015, “Real-Time Control of Soft-Robots Using Asynchronous Finite Element Modeling,” IEEE International Conference on Robotics and Automation (ICRA), Seattle, WA, May 26–30.10.1109/ICRA.2015.7139541

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2017, Soft Gripper Dynamics Using a Line-Segment Model With an Optimization-Based Parameter Identification Method, IEEE Rob. Autom. Lett., 2, 1909, 10.1109/LRA.2017.2714141

2016, Deformable Model-Based Methods for Shape Control of a Haptic Jamming Surface, IEEE Trans. Visualization Comput. Graph., 23, 1029, 10.1109/TVCG.2016.2525788

2017, Projection Kinematic Analysis of DNA Origami Mechanisms Based on a Two-Dimensional TEM Image, Mech. Mach. Theory, 109, 22, 10.1016/j.mechmachtheory.2016.11.010

2012, Design to Self-Assembly, Archit. Des., 82, 68, 10.1002/ad.1381

2015, 4D Printing Technology: A Review, 3D Printing Addit. Manuf., 2, 159, 10.1089/3dp.2015.0039

2017, GDFE: Geometry-Driven Finite Element for Four-Dimensional Printing, ASME J. Manuf. Sci. Eng., 139, 111006, 10.1115/1.4037429

2016, Multiprocess 3D Printing for Increasing Component Functionality, Science, 353, 10.1126/science.aaf2093

2017, Review of Optical Freeform Surface Representation Technique and Its Application, Opt. Eng., 56, 10.1117/1.OE.56.11.110901

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NASA/JPL-Caltech, 2017, Space Fabric' Links Fashion and Engineering

2016, Design and Simulation of 3D Printed Air-Cooled Heat Exchangers, Solid Freeform Fabrication

2017, Multi-Objective Optimization of Injection Molding Process Parameters for Short Cycle Time and Warpage Reduction Using Conformal Cooling Channel, Int. J. Adv. Manuf. Technol., 88, 1735, 10.1007/s00170-016-8904-x

2011, Automatic Design of Conformal Cooling Circuit for Rapid Tooling, Comput.-Aided Des., 43, 1001, 10.1016/j.cad.2011.04.011

2015, Spiral and Conformal Cooling in Plastic Injection Molding, Comput.-Aided Des., 63, 1, 10.1016/j.cad.2014.11.012

Zhang, X., Fang, G., Dai, C., Verlinden, J., Wu, J., Whiting, E., and Wang, C. C. L., 2017, “Thermal-Comfort Design of Personalized Casts,” 30th Annual ACM Symposium on User Interface Software and Technology, Québec City, QC, Canada, Oct. 22–25, pp. 243–254 .

2018, Concurrent Lattice Infill With Feature Evolution Optimization for Additive Manufactured Heat Conduction Design, Struct. Multidiscip. Optim., 58, 511, 10.1007/s00158-018-1905-7

2011, Conformal Printing of Electrically Small Antennas on Three-Dimensional Surfaces, Adv. Mater., 23, 1335, 10.1002/adma.201003734

2016, Instrumented Cardiac Microphysiological Devices Via Multimaterial Three-Dimensional Printing, Nat. Mater., 16, 303, 10.1038/nmat4782

2013, 3D Printed Bionic Ears, Nano Lett., 13, 2634, 10.1021/nl4007744

2017, Design Framework for Multifunctional Additive Manufacturing: Placement and Routing of Three-Dimensional Printed Circuit Volumes, ASME J. Mech. Des., 137, 98, 10.1115/1.4030996

2017, Design Framework for Multifunctional Additive Manufacturing: Coupled Optimization Strategy for Structures With Embedded Functional Systems, Addit. Manuf., 16, 98, 10.1016/j.addma.2017.05.009

2015, BionicANTs: Cooperative Behaviour Based on Natural Model

Vidimce, K., Kaspar, A., Wang, Y., and Matusik, W., 2016, “Foundry: Hierarchical Material Design for Multi-Material Fabrication,” 29th Annual Symposium on User Interface Software and Technology, Tokyo, Japan, Oct. 16–19.