La Metodologia del Design for Additive Manufacturing per la
Stampa 3D
GIORNATA DI FORMAZIONE
7 NOVEMBRE 2018PLASTICS SMART HUB 4.0
CESAP - MONZA
S I N C E 1998
Two decades of innovation, creative thinking, and value delivery
PRODUCT DESIGN & DEVELOPMENT
www.convercon.com
helps companies innovate
Società di servizi integrati di ingegneria e sviluppo prodotto, fondata nel 1998 daRoberto Pasceri, Amministratore Delegato.Paolo Golfarini da oltre 15 anni è il Direttore Tecnico e Responsabile dei Servizidi Consulenza e Formazione.
Opera in tutta Italia attraverso la sede di Bologna e in Asia con una società partner,tramite la filiale di Bangkok, Innovation Code Ltd.
Attualmente si avvale di un organico di oltre 20 persone che può arrivare a circa 40avvalendosi di qualificate collaborazioni che completano ed integrano la sua offerta.
WHO ?
www.convercon.com
Convergence Consulting S.r.l.helps companies innovate
WHAT ?
∎ Progettazione e Co-Progettazione: in outsourcing o presso la sede delcliente (knowledge sharing).Principali Cad utilizzati: Creo®, SolidWorks® ed NX®.
∎ Consulenza: Servizi di start up e impostazione metodologica, favorendo ladiffusione delle “Best Practices” in ambiente Creo Parametric®.Partnership Tecnologica e Progettuale a 360 gradi affiancando e supportando leaziende clienti con la metodologia del “training on the job”.
∎ Corsi di formazione: Corsi (Base, Avanzati e Personalizzati) Creo Parametric®.Metodologie innovative di progettazione 3D.
∎ Stampa 3D: Attività di affiancamento nella progettazione e sviluppo di nuovi prodottiutilizzando la tecnologia dell'additive manufacturing.
helps companies innovate
OUR FOCUS!
helps companies innovate
COMPONENTS ASSEMBLIES ADDITIVE MANUFACTURING
AGILITY & LEAN DESIGN
HOW ?
helps companies innovate
BREAKTHROUGH TECHNOLOGY
AGILITY & LEAN DESIGN
Modello 3D completo di:
– quote;
– tolleranze dimensionali
– tolleranze geometriche;
– note e segni di lavorazione
Permette:
• Tempi di sviluppo progetto fortemente ridotti• Realizzare il disegno bidimensionale può
diventare superfluo• Migliore qualità del progetto• Riduzione delle modifiche tecniche dopo il
lancio in produzione• Standardizzazione di processi, persone e
metodologie
Un modello digitale corretto costituisce il primopassaggio nell’ambito dell’ottimizzazione delprocesso di sviluppo prodotto.
COMPONENTShelps companies innovate
PROGETTAZIONE TOP – DOWN
Viene innanzitutto definita la struttura del prodotto,ovvero l'organizzazione dei principali sottoassiemi ealtri componenti, senza concentrarsi sulla geometriadelle singole parti. Le ossature (skeleton) ricevonola geometria che riguarda più assiemi e parti.In questo modo, possiamo implementare lemodifiche al livello più alto e i componentiinterconnessi si aggiornano in base a pianificazionie aspettative.
Vantaggi:‒ Permette di porre l’attenzione sull'obiettivo e non
sul metodo costruttivo.‒ La modellazione avviene nel contesto di
assieme: come si faceva col CAD 2D, si progettadirettamente nell’assieme.
‒ Posizioni e dimensioni dei componenti possonoessere definite attraverso “Scheletri” (o “Layout”),
aumentando così la “robustezza” dell’assieme.
ASSEMBLIEShelps companies innovate
AGILITY & LEAN DESIGN
ADDICTIVE TO ADDITIVE MANUFACTURING !
Additive Manufacturing è una tecnologia dirompente e abilitante, in quanto ha il
potenziale per sostituire molti processi manifatturieri convenzionali e far
prosperare nuovi modelli di business, nuovi prodotti e nuove supply chain.
helps companies innovate
BREAKTHROUGH TECHNOLOGY
• Speedtime-to-market– Increase engineering productivity and efficiency
• Reduceproductdevelopmentcost– Eliminate lengthy design and development cycle times
• Acceleratenewproductintroduction– Rapidly solve for design requirements and develop new
products
• Increasedesigninnovationandimproveperformance– Eliminate influences and solving for design objectives
(i.e., carry-over geometry, pre-conceived modeling & mfg.considerations)
• Increasesales,revenueandcustomerloyalty– Innovative products are easily differentiated in the market
place
• Rapidcreationofdesignconceptsandprototypegeometry– Early stage and frequent prototyping leads to more
effective product launches and increased innovation
• Directdigitalmanufacturing(DDM)ofend-usesellableproducts– Cost effectively manufacture highly complex geometry– DDM opens the door for new opportunities and business
models– Cost effectively produce custom and low volume products
• Directdigitalmanufacturingofsofttooling– Fast, low-cost production of short run production tooling
• Increased“designfreedom”– Create innovative products that could not be conceived
using traditional manufacturing processes
• Costreductionthroughpartconsolidation
- Consolidate multi-part assemblies to a single part byremoving manufacturing limitations
helps companies innovate SOME ADVANTAGES
CREO DESIGN FOR ADDITIVE MANUFACTURING
9
• Light weight designs without compromising stress and
displacement requirements
– Integrated design-analysis process
• Simulate using additive manufacturing material properties
• Design to self-supporting geometries, or minimize support
structures
• Simplify assemblies
– Part consolidation, more functions in each part
• Biomimetic’s
• …
“Beast” (2010), Museum of Science, Boston. Neri
Oxman
helps companies innovate SOME FURTHER ADVANTAGES
CREO DESIGN FOR ADDITIVE MANUFACTURING
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CAD Model
3D Printer
Design to print workflow
CAD Domain
CREO DESIGN FOR ADDITIVE MANUFACTURINGhelps companies innovate CLOSING THE GAP
Slicing
Topology Optimization
Creo’s value proposition is centered in closing the gap between CAD and the 3D Printer
TOPOLOGY OPTIMIZATION (AMX)
Permette di realizzare automaticamente progetti ottimizzati basati su una serie definita di vincoli, obiettivi elimiti, indipendentemente dai progetti esistenti e da limiti concettuali.
helps companies innovate
CREO DESIGN FOR ADDITIVE MANUFACTURING
Easy of Use:Fast optimization setupRapid topology optimizationSemi-automated CAD reconstruction
Familiar Creo interaction and workflow
Fast optimization setup:
Define fixed and free geometryEasily define volume regions(geometry is excluded from optimization)
Easy load and constraint definitionApply loads and constraints to defininggeometryDefine fabrication constraints to influenceshape
Automatic mesh generationMesh control and diagnostics tools
Rapid topology optimization
Simple dialog to define optimization studyTopology RegionsDesign ObjectivesDesign Constraints
Proven technology powered by VR&D(Vanderplaats Research & Development,Inc.)
Comprehensive results interrogation toolDynamic sectioning and stress displayAbility to view deformed
helps companies innovate
CREO DESIGN FOR ADDITIVE MANUFACTURING
Topology Optimization delivers…
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Creo’s value proposition is centered in closing the gap
CAD Model
ModelPreparation
e.g. define theinterior
Tray placementPrintability Checking
e.g. thin walls3D Printer
Goal: bring the knowledge ofAdditive Manufacturing capabilitiesearly into the design process
Print what you design
CAD Domain CAD Domain
Slicing
helps companies innovate
between CAD and the 3D Printer
CLOSING THE GAPCREO DESIGN FOR ADDITIVE MANUFACTURING
Design to print workflow
LATTICE (AMX)E’ un modulo che permette di migliorare le prestazioni meccaniche di un oggetto sostituendo al pieno un reticolo diforme e geometrie differenti.
CREO DESIGN FOR ADDITIVE MANUFACTURINGhelps companies innovate
LATTICES FOR 3D PRINTING
• 2 ½ D lattices– Multiple 2D cells (triangular, honeycomb..)
Optional image
2 ½ D LATTICES
3D LATTICES
CONTROL ON 3D LATTICES
helps companies innovate
CREO DESIGN FOR ADDITIVE MANUFACTURING
• 3D Lattices– Multiple 3D cells (hexagonal, octagonal...)
– Remove dangling beams option
2 ½ D LATTICES
3D LATTICES
CONTROL ON 3D LATTICES
helps companies innovate
LATTICES FOR 3D PRINTING
CREO DESIGN FOR ADDITIVE MANUFACTURING
• 3D Lattices– Beam cross sections
• circular, square and hexagonal
– Beam profiles options• Straight. Circular, square and hexagonal
• Parabolic. circular
2 ½ D LATTICES
3D LATTICES
CONTROL ON 3D LATTICES
helps companies innovate
LATTICES FOR 3D PRINTING
CREO DESIGN FOR ADDITIVE MANUFACTURING
• You can create lattice with varied density. The density
is set by the cross section size of the beams.
• Cutoff parameter– It will eliminate those beams below the specified
diameter value
Optional image
2 ½ D LATTICES
3D LATTICES
CONTROL ON 3D LATTICES
VARIABILITY CONTROL ON 3D LATTICEShelps companies innovate
CREO DESIGN FOR ADDITIVE MANUFACTURING
• Parabolic beams can work nicely with variability
controls
Optional image
2 ½ D LATTICES
3D LATTICES
CONTROL ON 3D LATTICES
helps companies innovate
VARIABILITY CONTROL ON 3D LATTICES
CREO DESIGN FOR ADDITIVE MANUFACTURING
• The lattice feature can be analyzed and optimized
using Creo simulate
• The lattice feature parameters are exposed to be used
along BMX experiments
ANALYSIS RESULTS
IDEALIZED ELEMENTS
FULL GEOMETRY
helps companies innovate
CREO SIMULATE AND BMX CAN DRIVE THE LATTICE
DEFINITION
• Idealized elements– Automatic conversion of the lattice into beams, masses
and shells.– Faster results, lightweight geometry transfer to Creo
Simulate
ANALYSIS RESULTS
IDEALIZED ELEMENTS
FULL GEOMETRY
helps companies innovate
LATTICES ANALYSIS AND OPTIMIZATION
CREO DESIGN FOR ADDITIVE MANUFACTURING
• Fine control over where to apply loads and constraints
into the Lattice feature– Each beam end-point have a datum point assigned on
the open side of the lattice– Those datum points can be used to define the load and
constraints
ANALYSIS RESULTS
IDEALIZED ELEMENTS
FULL GEOMETRY
helps companies innovate
LATTICES ANALYSIS AND OPTIMIZATION
CREO DESIGN FOR ADDITIVE MANUFACTURING
• Full geometry
– Use the mesher capabilites of Creo Simulate– More refined model, ideal for the final optimization
cycle
ANALYSIS RESULTS
IDEALIZED ELEMENTS
FULL GEOMETRY
helps companies innovate
CREO DESIGN FOR ADDITIVE MANUFACTURING
LATTICES ANALYSIS AND OPTIMIZATION
• Printability validation– We can check for thin walls and narrow gaps
• 3D printing preview– We can visualize the theoretical support structure– We can define the tessellation parameters selectivelly
• Add printers
• Basic functionality to add notes
PRINTABILITY VALIDATION
3D PRINT PREVIEW
NOTES
helps companies innovate
TRAY ASSEMBLY (AMX)
CREO DESIGN FOR ADDITIVE MANUFACTURING
• A repository of parts/assy
• An assembly subtype
• Nesting/auto-position
REPOSITORY OF PARTS/ASSY
AN ASSEMBLY SUBTYPE
NESTING/AUTO-POSITION
helps companies innovate
TRAY ASSEMBLY (AMX)
CREO DESIGN FOR ADDITIVE MANUFACTURING
NESTING (AMX)
Utilizzando algoritmi avanzati analizza le forme da produrre, determinandone quindi, in modo intelligente, la posizione ottimale alfine di ridurre al minimo i supporti ed i tempi di esecuzione.
helps companies innovate
CREO DESIGN FOR ADDITIVE MANUFACTURING
helps companies innovate
THE CHALLENGE
V.U.C.A.Volatile, Incerto (Uncertain), Complesso e Ambiguo
L'agilità organizzativa, ovvero la capacità di adeguare e adattarecontinuamente gli strumenti, le competenze ed i modelli di riferimento nelproprio core business, è sempre più considerata il fattore vitale di successoaziendale.
helps companies innovate
La capacità di cambiamentocontinuo ed efficace èl’elemento chiave per lasopravvivenza ed il successo.
helps companies innovate
L'unica certezza è che i nostriabituali processi e modi dilavorare, molto probabilmente,non sono più i modi migliori.
THE CHALLENGE
We are here to help you to
Close the Gap between your Comfort Zone and the Future
helps companies innovate
CLOSING THE GAP