OverHiPP, or to be extra exact, Over-printing with Excessive Efficiency Polymers, is a 2-year Innovate UK funded undertaking. GRM is one in every of six undertaking companions concerned, together with a various advisory board. The purpose of OverHiPP is to develop and optimise a brand new hybrid manufacturing method for overprinting 3D printed materials onto composite sheets. Over-Printing is a brand new strategy that takes the advantages from a lot of current methods, particularly from over-moulding, resin switch moulding (RTM) and 3D printing. The advantages of this strategy embody low tooling prices, elevated flexibility, fast changeover of fabric and low materials waste. One problem with it, nevertheless, is the restricted data and applied sciences accessible.
Latest developments in 5 axis 3D printing {hardware} have enabled initiatives to push the technological limits additional by lowering the necessity for help buildings; manufacturing shapes not beforehand potential, even with typical 3D printing; and, pertinently, over-printing materials onto current elements. Nonetheless, simulation methods for such 3D printed buildings haven’t developed on the similar tempo. It is a key space that GRM has been engaged on options.
GRM Consulting is a specialist design and topology optimisation software program firm, with in depth data and expertise in growing Finite Aspect Evaluation (FEA) programmes throughout a variety of disciplines. The corporate has been central to growing new software program for the OverHiPP undertaking to supply perception, steering and confidence in 3D printed elements by enhancing the accuracy of digital twins.
The instrument path and infill patterns make 5 axis 3D printed buildings extremely anisotropic in nature. This may make it tough to precisely mannequin these properties right into a digital twin and achieve perception into structural efficiency and failure modes. Furthermore, it’s virtually unimaginable for a human to manually mannequin the right materials orientation onto every factor in an FE mannequin. GRM has solved this drawback by growing software program that may routinely replicate a toolpath in an FE mannequin. Based mostly on a proprietary G-Code reader that may analyse and decide instrument path properties earlier than changing it into digital twin format it permits for the exact filament orientations and infill cavities to be thought of when working structural simulations.
GRM has rigorously examined its outcomes. One such take a look at investigated the feasibility of 3D printing a hyper-car foot relaxation. This included a lot of topology optimisation research being investigated to find out key load paths and structural efficiency. The ultimate outcomes had been interpreted and modelled by GRM for manufacture.
The examine aimed to find out the optimum construct instructions utilizing the minimal quantity of fabric to finest help the assessed load instances.
From this, a CAD mannequin was then created in SolidWorks based mostly on the topology outcomes, prepared for manufacture on the Centre for Additive Layer Manufacturing (CALM) at Exeter College utilizing a high-temperature polyamide from Lehvoss. Native options, equivalent to shoulder bolt mounts, had been added and Design for Manufacture (DfM) drawings had been generated.
It was clear from each the simulation and take a look at outcomes {that a} five-fold distinction was present in each the stiffness and energy efficiency when printing in poor and optimum instructions.
As a part of the OverHiPP undertaking, GRM has enabled customers to just about mannequin and analyse 3D printed buildings at a degree of element by no means seen earlier than. An correct digital twin can now be generated, permitting for exact design selections to be made, by creating up to date Nastran/Abaqus fashions. All of those software program options have robust correlation to bodily checks, proving their validity. Completely different printing methods can now be studied intimately, by assessing weak factors and failure modes for every variant earlier than manufacturing providing higher efficiencies within the workflow and extra constant, profitable outcomes.
For extra data: www.grm-consulting.co.uk
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