Digital Manufacturing and Design Workflows to Enable
New Product Innovations
Lim Keng Hui Director, DManD & NAMIC@SUTD [email protected]
Content
• Introduction to SUTD
• Digital Manufacturing & Design Centre (DManD) – Overview
– Advances in AM / 3D printing
• NAMIC and Industry Partnerships
2
A Better World by Design: Educating Technically-grounded Leaders and
Innovators for the 21th Century
An Outside-In Curriculum
Design projects Electives
Architecture &
Sustainable
Design
Engineering
Product
Development
Engineering
Systems &
Design
Information
Systems
Technology &
Design
Senior
Junior
Sophomore
Freshmore
Capstone: Integrated Design Experience
• Four 12-unit subjects per semester ( x 8 semesters) 22% humanities courses
Statistical Reasoning and Optimization
Archi- tecture
Core
Product Design Core
System Design Core
Info Design Core
Entrepreneurship, Management, Social Science, Economics, Humanities, Arts
Energy & Structures
Dynamics & Control
Linear Signals & Systems
Information, Computation, Materials and Systems
FOUNDATIONS Mathematics, Science, Introductory Humanities, Social Sciences
in the context of Design
Digital World Physical World Systems World
Active and Collaborative Learning
• Student-faculty ratio of 11:1
• Integrating lectures, recitations and design projects (Learn, Engage and Apply)
• Group learning & peer support
• Ready access to fabrication equipment
Digital Manufacturing & Design Centre (DManD)
DManD Positioning
Vision for Digital Manufacturing
v. 1.0
Advance frontiers in design and manufacturing enabled by the digital thread that integrates the product innovation and development value chain.
Approaches to Design & Manufacturing
Design Innovation
Materials Selection
Manufacturing Method
• Mostly sequential process • Few interactions • Limits design freedom
• Non-sequential process • Creates interactions • New degrees of freedom • Expands design freedom & facilitates innovation
Old Design dictates materials and manufacturing selection
New Manufacturing and materials differentiate product design
Ref from IRI Keynote, Nov 2011
Design Innovation
Materials Innovation
Manufacturing Innovation
Digital Workflows
DManD Research
Geometry Composition Performance & Function
Stratasys, 2015 Multimaterial joint
Kaijima, SUTD
Soft robot
Alvarado, SUTD
Rocket fuel
Gilmour, SUTD
3D printed battery
Yang, SUTD
✔ ✔ ✔
Geometry & Information Acquisition
Computational Engineering
Digital Fabrication & Assembly
Digital Design
Computational Manufacturing
Testing and Characterization Materials
Digital workflows that integrate Design – Materials – Manufacturing Innovations to accelerate next-gen product development
High-res multimaterial 3D printing
4D Printing: smart actuating materials
! ! !
! 29!
As!an!extension!of!our!topology!optimization!approaches!in!Thrust!1.2,!we!will!develop!an! approach! to! design! the! optimum! layout! of! fibers! in! a! composite! in! 2D!lamina/laminates! as!well! as! general! 3D! solids.! !One! approach!we!will! pursue! is:! i)!mathematical!homogenization!to!describe!an!anisotropic!composite!as!an!anisotropic!solid!at!the!level!of!a!3D!voxel,! ii)!a!topology!optimization!(Thrust!1.2)!approach!to!determine! the! optimal! stiffness! tensor! (or! orientation@dependent! property),! iii)! a!computer!graphics!approach!similar!to!that!used!in!diffusion!tensor!imagining!of!tissue!to! then! create! physical! fiber! and! fiber! bundle! realizations! from! the! optimal!homogenized!solution,!and! then! iv)!middleware! to!print!using!our! technology! to!be!developed.!!Preliminary!efforts!are!shown!in!Fig.!7;!while!the!representation!is!visually!descriptive,!it!can!not!be!realized!physically!and!our!efforts!here!will!make!this!possible.!!
!!Fig.!7!Preliminary!a!homogenization@based! topology!optimization!approach! to!determine! the!optimal!anisotropic!stiffness!distribution!of!a!component!at!the!voxel!scale!and!then!generate!fiber!bundles!with!a!spatially@varying!volume!fraction!f!that!can!be!printed!is!shown!in!Fig.!7.!!We!will!pursue!a!second!approach!for!individual!fibers!that!may!be!structural!or!more!importantly!functional,!e.g.,!electrical.!!Here!we!will!represent!fibers!as!nonlinear!elastic!and! form!mathematical! optimization! problems! to! determine! optimal! layouts! in! 3D!space!consistent!with!compatibility!with!a!possibly@deforming!3D!printed!solid.!!!Our!efforts!will!focus!on!structural!fibers!to!begin,!e.g.,!glass,!carbon,!and!aramid,!but!we!will!then.!!We!plan!to!pursue!Aracon!metal@coated!aramid!fibers!to!create!integrated!structural!composites!with!integrated!electrical!wiring!within!complex!3D!geometries.!!Recent!investments!in!these!fibers!is!rapidly!bringing!the!cost!down!so!that!they!are!likely!to!emerge!as!next@generation!manufacturing!staples.
!Exploitable Outcomes:!New!capabilities!that!will!allow!transition!of!existing!printed!plastics!to!robust!structural!materials,!optimized!light@weight!structures!for!products,!and! complex! 3D! multifunctional! structures;! technology! that! allows! increased!integration!of!prototyping!with!final!manufacturing!by!being!able!to!prototype!in!plastic!and! then! immediately! manufacture! with! carbon! fiber;! technology! to! manufacture!!integrated! structures! with! multifunctional! fibers! for! sensing,! actuation,!communications,! etc.,! new! joining! methodologies! for! composites! enabled! by! direct!printing!of! fiber!composite;!design!software!for!optimal! fiber!placement!that!can!be!used!with!existing!robotic!fiber!laying!machines.!!!!!!
Design & optimization: mechanical, thermal, fluidics, aesthetics
3D printed batteries, sensors & electronics
Easy to use software tools for complex design
Nano-mfg of functional surfaces, e.g. color, self cleaning
Soft Engineering & Robotics
Digitized textured surfaces
3D Composites & Textiles
Generative design Design for Additive Mfg
3D scanning & automated reconstruction with AI & VR/AR
Robotics & hybrid processes
DesignInnova on
MaterialsInnova on
ManufacturingInnova on
DigitalWorkflows
Additive Manufacturing Value Propositions
1. Accelerating product development
2. Reducing cost for HMLV manufacturing
3. Exploiting design freedom
4. Developing new applications
5. Simplifying supply chain, reducing lead times
Source: PADT, Inc
Value Propositions
1. Accelerating product development 2. Simplifying supply chain, reducing lead times & inventory 3. Reducing cost for HMLV manufacturing
Product Development process showing the role of prototypes (most often 3D printed) Assembly consolidation
(e.g. Fuel assembly system with reduced number of parts; Embedded electronic products)
Value Propositions
4. Exploiting design freedom
Complex design, internal features, reduced part numbers (e.g. ultra-strong & light materials; exhaust gas probe with complex features)
Strength-to-weight optimisation (e.g. brackets)
Multi-material, multi-functional manufacturing (e.g. 3D printed electronics embedded, advanced composite structures)
Bio-inspiration (e.g. leveraging lattice designs, functional nano-surfaces)
Value Propositions
5. Developing new applications
Soft robots and customised smart products
Smart objects via functional & multimaterial printing, e.g. self assembly, shape changing products
Zoomorphic Design
• Noah Duncan, Lap-Fai Yu, Sai-Kit Yeung,
Demetri Terzopoulos
• First computational Approach in Designing
Zoomorphic Shape
Rapid and easy-to-use design tools, e.g. personalised products
3D printed UAV
AM @ DManD
Additive Manufacturing @ DManD
DMD
UV
Continuous Fiber Composite Printing MarkForge M1
Inkjet Printing
Direct Metal Laser Sintering (DMLS) EOSINT M280
Fused Deposition Modeling Printing Stratasys Fortus 450mc
Polyjet Printing, Multimaterial, Full Color Stratasys J750
Aerosol Jet Electronics 3D Printing
Two-Photon Photopolymerisation Nanoscribe
Multimaterial Projection Micro Stereolithography (MPµSL)
In-house developed, example:
Multimaterial Rocket Fuel Grain Printing
Polymer Metal Fiber Composite Electronics & Ink
Other printing technologies, e.g. SLA
Polymer Fibre-Reinforced Laser-Sintering EOS P396
Multijet Fusion HP
• Design for Additive Manufacturing
• Additive Manufacturing Processes
0 10 20 30 40 0 5 10 15 20 25 30 35 40 45 50
1
2
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41.3
41.5
Design for Additive Manufacturing
Rosen, D. R.
Design for Additive Manufacturing
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Standards for Design Rules for AM
• Develop international standards (ISO & ASTM) for Design rules for AM, including design principles and design for powder bed fusion, SLA and FDM ☞ Promote adoption of AM through propagation of design standards for AM
Design for AM of integrated pressure regulator for composite pressure vessel
• Develop (a) synergistic functionalities for composite & AM; (b) design guidelines for composite-AM devices.
☞ Potential use in fuel-cell tech. & automotive CPV.
Current carbon fiber-reinforced composite pressure vessel designs with protruding pressure regulator
Integrated pressure regulator design: ▶ weight reduction ▶ improved packaging & safety
SME
Design for metal AM for rapid supports removal SME
3D printed part (left) with support structures removed very rapidly, including inner features
• Develop easy-to-remove support structure design & removal process for metal 3D printing. ☞ Improve efficiency & cost-effectiveness of metal printing by minimising post-processing effort.
Design for Additive Manufacturing
Design & devt of agile electric Portable Utilitarian Vehicle (PUV)
• Design & fabricate exterior covers for various configurations at low-cost and high speed.
Showpiece at CommunicAsia 2017
Start-up
Adoption of 3D printing allows prototyping & design configuration studies to be carried out at lower cost & low-vol. runs cf. injection molding.
Design for multi-material, multi-colour parts for life-like visual effect SME
• Design for AM with multi-material, multi-colour attributes & achieving life-like visual effect. ☞ Potential use in automating fabrication of prosthetics and human organ models for surgical planning.
For illustration Pictures obtained from various sources
Artificial eye: Conven- tional manual process
AM-fabricated eye - Features close to actual eye, with improved accuracy
Geometric Modeling
Simulation Material Design for smooth deflection
Kajima et al., 2016
Homogenous structure – odd deflection
Optimised composite structure
• Design and model architecture and
layout of carbon fiber reinforced
composite for UAV components
• Fabrication of large composite UAV
components
3D printing
(FDM) with
continuous
fiber
reinforced
polymer
(Markforge)
UAV Composites
Multimaterial Design & AM
“AM-aware”
Computer-Aided
Design
Input image
50 100 150 200 250
50
100
150
200
250
Process Design
Find: process variables
Satisfy: process constraints
Minimize: time, cost
Materials Design
Find: volume fractions, grain
size, shape
Satisfy: compatibility
constraints
Maximize: energy absorption,
mech properties
Part/Product Design
Find: dimension values
Satisfy: stress, strain
Maximize: energy
absorption
Process ↔ Structure ↔ Property ↔ Performance
Design Problem
Formulation
Multi-Objective
Optimization
Methods
Encoding of microstructure using
Surfacelet coefficients
“Zoom-in” and “Zoom-out” operations
enabled by Surfacelet
CAD methods enabled by geometric model
Integrated Product – Material – Process – Design Method
New Frontiers in AM - 4D Printing - Printed Power - Soft Robotics
Common practice:
Discrete motors, pumps, voice
coils, gears, bearings,
sensors, etc
Desired practice:
Smart materials that actuate,
transform and self-assemble based on
desired design, are light-weight and simple
to integrate
Automotive:
Responsive car
aero foil
Aerospace:
Morphing wings
concept (NASA)
Medical:
Self deploying
medical devices
Complex mechanism,
needs assembly, many
moving parts…
4D printing
3D Printing Active Materials 4D Printing +
Shape memory polymer (SMP)
Shape change with “time”
Ge Qi, et al
4D
Printing
3D Printing
Approaches
Material
Development
Modeling
and
Simulation
4D Printing DMD Toolchain & Workflow
Multimaterial Polyjet printing
Formulate new materials
Digital composites
Material A
Material B
Composites (@ voxel control)
A B
Multimaterial Projection Micro Stereolithography
Thermomechanical constitutive modeling
Multiphysics Topology Optimization
4D printing enables creation of light-weight, inexpensive and simple to integrate actuating and
transforming components which may find applications in
Potential Applications of 4D Printing
Biomedical device
Self-folding/unfolding robots
Soft Robots
Potential
applications of
4D printing
Morphing wings Deployable structure
Foldable Furniture
*Industrial projects
Advantages for 3D printed LIBs
3D electrodes design: High areal-loading density (high energy density) Short ion-diffusion distance (high power density)
3D printed LIBs: Top-down technology Controlled pattern, shape. Fast prototyping. Compatible with whole printing electronics. Print solid electrolyte to solve safety issue. Print package with special functions, such as self-healing.
http://www.3ders.org/articles/20141024-graphene-3d-lab-unveils-first-3d-printed-graphene-battery.html
3D Printed Power – LIBs
Advantages for 3D printed LIBs
3D electrodes design: High areal-loading density (high energy density) Short ion-diffusion distance (high power density)
3D printed LIBs: Top-down technology Controlled pattern, shape. Fast prototyping. Compatible with whole printing electronics. Print solid electrolyte to solve safety issue. Print package with special functions, such as self-healing.
http://www.3ders.org/articles/20141024-graphene-3d-lab-unveils-first-3d-printed-graphene-battery.html
Wang Y. et al. Advanced Energy Materials
3D Printed Power – LIBs
•Printing process to create 3D battery as power source for micro-electronics
•Direct ink writing (DIW) method
•Design freedom: high flexibility in size & shape of the battery; printing on various substrates, and even curved surface
Robot
Direct Write 3D Printer
Accomplishment: 3D Printed micro-LIBs
Dispenser
Robot
Various substrates
Glass
PET
Printed single layer
Printed Micro-LIBs: Multi layers
6-layer, printed PDMS package
Industry project: Freeform 3D printed batteries for micro-electronics in drones
• Commercial space launch vehicles employing a proprietary
hybrid rocket technology
• Multi-material hybrid fuel grains that are designed and 3D
printed
3D Printing of Hybrid Rocket Fuel
Test rocket successfully launched in Queensland, Australia in Jul 2016. - 3D-printed fuel technology - 3.6m rocket | 5km
Multimaterial printer
Hybrid fuel grain
Lim, et al
Example
Thrust schedule created by designing interior propellant geometry
Stretchable conductive circuit
Ge et al. Scientific Report, 2016.
unpublished
Soft Robotics – Functional Materials
Smart Materials / 4D Printing • Large deformations in response
to heat, moisture, electricity, etc. • Can generate stresses required
for actuation.
3D printable hyperelastic soft materials • Deformations of more than 10 times its
initial length • Can accommodate large strains needed
for actuation (e.g. pneumatic soft actuators)
Conductive stretchable materials • Highly stretchable & 3D printable
electric conductors. • Can provide the structure for flexible
circuits and sensors
Scientists produce
world’s most
stretchable 3D
printable elastomer
Applications in Manufacturing
Soft robotic grippers: Adaptive grippers that conform to irregular & delicate objects
2. Fully 3D printed pneumatic-
based grippers
1. Cable-driven high payload grippers
New approaches to design and fabricate actuation, locomotion and sensing mechanisms in multimaterial soft systems & products
• Internship Opportunities • Capstone Projects • Sponsor PhD students through IPP • Collaborative Research Projects
– Option for company to own the FIP, depending on the funding structure
• Research Programs, Joint Labs / Corp Labs
SUTD – Partnering Industry
• National Additive Manufacturing Innovation Cluster (NAMIC) is a National Initiative to accelerate translation of upstream 3D printing research into commercial applications for industry adoption.
NAMIC Introduction
NAMIC Hub NAMIC Hub
3D printing initiative for Medical Technologies
Singapore Centre for 3D Printing (SC3DP)
Digital Manufacturing & Design Centre
NAMIC Hub
Industry Development 1. Raise awareness, training and certification of professionals 2. Promote adoption of AM across various industries, e.g. industrial collaboration projects
Technology Development 4. Translate IPs of high commercial potential and industry relevance 5. Develop new industrial standards for AM (local and international)
NAMIC Funding & Project Evaluation Process
NAMIC HUB • Problem Statement
Definition • Project Scoping,
Structuring, Management and Execution
• Industry Capability Development
• Competency Creation • Commercialization
Planning and Support
Industry Partners
Ecosystem Partners
Research Performers
Project Evaluation and Selection
• Industrial Implementation
• Commercial Product
• New Business • Start-ups &
Spinoffs
Project Execution
Commercialisation
NAMIC provides matching funding up to $250K for R&D projects in AM
* Shows examples
Our Partners*
Acknowledgements
• NRF, MOE, NAMIC, EDB, SPRING
Our Team*
Thank You