Project number
25507
Organization
Cummings Aerospace
Offering
ENGR498-S2025-F2025
Problem Statement:
With the advent of 3D printing, it is possible to fabricate component designs that until now have been impossible to make. In addition to the 3D printing capabilities that now exist, analysis software also exists that performs Topological Optimization, routines that minimize the use of the material used in fabrication. This combination of 3D Printing and Topological Optimization is the Holy Grail of additive manufacturing. There is one problem, however. The topological optimization generally results in a solid structure, but the 3D printers have the ability to create components that have variable amounts of internal structure to optimize print time and minimize material usage. And these components may perform very differently in use when compared to the solid structure previously analyzed.
Project: Develop a method to perform structural analysis of 3D printed polymers (PLA, ULTEM) using FDM processing. Produce prototype hardware to demonstrate the methodology. And document the methodology such that the approach can be integrated with other analysis tools, like Ansys and SolidWorks.
Skills Required: Structural analysis experience using Finite Element modeling (FEM), working knowledge of 3D printing (slicers, printers, etc), experience with CAD software (Solidworks, Creo, Inventor, etc), and experience with analysis software (Ansys, Simulia, etc).
With the advent of 3D printing, it is possible to fabricate component designs that until now have been impossible to make. In addition to the 3D printing capabilities that now exist, analysis software also exists that performs Topological Optimization, routines that minimize the use of the material used in fabrication. This combination of 3D Printing and Topological Optimization is the Holy Grail of additive manufacturing. There is one problem, however. The topological optimization generally results in a solid structure, but the 3D printers have the ability to create components that have variable amounts of internal structure to optimize print time and minimize material usage. And these components may perform very differently in use when compared to the solid structure previously analyzed.
Project: Develop a method to perform structural analysis of 3D printed polymers (PLA, ULTEM) using FDM processing. Produce prototype hardware to demonstrate the methodology. And document the methodology such that the approach can be integrated with other analysis tools, like Ansys and SolidWorks.
Skills Required: Structural analysis experience using Finite Element modeling (FEM), working knowledge of 3D printing (slicers, printers, etc), experience with CAD software (Solidworks, Creo, Inventor, etc), and experience with analysis software (Ansys, Simulia, etc).