Digital Manufacturing and Design Workflows to Enable New Product Innovations. Lim Keng Hui Director, DManD &

Transcription

1 Digital Manufacturing and Design Workflows to Enable New Product Innovations Lim Keng Hui Director, DManD &

2 Content Introduction to SUTD Digital Manufacturing & Design Centre (DManD) Overview Advances in AM / 3D printing NAMIC and Industry Partnerships 2

3 A Better World by Design: Educating Technically-grounded Leaders and Innovators for the 21 th Century

4 An Outside-In Curriculum Architecture & Sustainable Design Engineering Product Development Engineering Systems & Design Information Systems Technology & Design Senior Capstone: Integrated Design Experience Entrepreneurship, Management, Social Science, Economics, Humanities, Arts Junior Architecture Core Energy & Structures Product Design Core Dynamics & Control System Design Core Linear Signals & Systems Info Design Core Sophomore Statistical Reasoning and Optimization Information, Computation, Materials and Systems Digital World Physical World Systems World Freshmore FOUNDATIONS Mathematics, Science, Introductory Humanities, Social Sciences in the context of Design Design projects Electives Four 12-unit subjects per semester ( x 8 semesters) 22% humanities courses

5 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

6 Digital Manufacturing & Design Centre (DManD)

7 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.

8 Approaches to Design & Manufacturing Old Design dictates materials and manufacturing selection New Manufacturing and materials differentiate product design Design Innovation Design Innovation Materials Selection Manufacturing Method Digital Workflows Manufacturing Innovation Materials Innovation Mostly sequential process Few interactions Limits design freedom Ref from IRI Keynote, Nov 2011 Non-sequential process Creates interactions New degrees of freedom Expands design freedom & facilitates innovation

9 DManD Research Digital workflows that integrate Design Materials Manufacturing Innovations to accelerate next-gen product development Digital Design Computational Manufacturing Geometry & Information Acquisition Computational Engineering Digital Fabrication & Assembly Materials Testing and Characterization Geometry Composition Performance & Function Stratasys, 2015 Multimaterial joint Kaijima, SUTD Soft robot Alvarado, SUTD Rocket fuel Gilmour, SUTD 3D printed battery Yang, SUTD

10 descriptive,!it!can!not!be!realized!physically!and!our!efforts!here!will!make!this!possible.!! Generative design 3D scanning & automated reconstruction with AI & VR/AR!! Design & optimization: anisotropic!stiffness!distribution!of!a!component!at!the!voxel!scale!and!then!generate!fiber!bundles!with!a! mechanical, thermal, fluidics,! We!will!pursue!a!second!approach!for!individual!fibers!that!may!be!structural!or!more! aesthetics importantly!functional,!e.g.,!electrical.!!here!we!will!represent!fibers!as!nonlinear!elastic! and! form! mathematical! optimization! problems! to! determine! optimal! layouts! in! 3D! Our!efforts!will!focus!on!structural!fibers!to!begin,!e.g.,!glass,!carbon,!and!aramid,!but!we! 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! Design Exploitable Outcomes:!New!capabilities!that!will!allow!transition!of!existing!printed! Innova on 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! Digital Workflows printing!of!fiber!composite;!design!software!for!optimal!fiber!placement!that!can!be! used!with!existing!robotic!fiber!laying!machines.!!!!!! Manufacturing Innova on Easy to use software tools for complex design Materials Innova on Design for Additive Mfg Digitized textured surfaces High-res multimaterial 3D printing! 4D Printing: smart actuating materials Nano-mfg of functional surfaces, e.g. color, self cleaning Robotics & hybrid processes 3D Composites & Textiles Soft Engineering & Robotics 3D printed batteries, sensors & electronics

11 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

12 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)

13 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)

14 Noah Duncan, Lap-Fai Yu, Sai-Kit Yeung, Demetri Terzopoulos Value Propositions First computational Approach in Designing Zoomorphic Shape 5. Developing new applications Smart objects via functional & multimaterial printing, e.g. self assembly, shape changing products Rapid and easy-to-use design tools, e.g. personalised products 3D printed UAV Soft robots and customised smart products

15 DManD

16 Additive DManD Polymer Metal Fiber Composite Electronics & Ink Polyjet Printing, Multimaterial, Full Color Stratasys J750 Direct Metal Laser Sintering (DMLS) EOSINT M280 Continuous Fiber Composite Printing MarkForge M1 Aerosol Jet Electronics 3D Printing Fused Deposition Modeling Printing Stratasys Fortus 450mc Inkjet Printing Multijet Fusion HP Polymer Fibre-Reinforced Laser-Sintering EOS P396 In-house developed, example: Multimaterial Projection Micro Stereolithography (MPµSL) DMD UV Multimaterial Rocket Fuel Grain Printing Two-Photon Photopolymerisation Nanoscribe Other printing technologies, e.g. SLA

17 Design for Additive Manufacturing Design for Additive Manufacturing Additive Manufacturing Processes Rosen, D. R.

18 Design for Additive Manufacturing Standards for Design Rules for AM Design for AM of integrated pressure regulator for composite pressure vessel SME R1 : M1( OH1) LessThan ( UC1,30) M 2( SU1) R2 : M1( OH1) GreaterThan ( UC1,30)... 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 Current carbon fiber-reinforced composite pressure vessel designs with protruding pressure regulator Integrated pressure regulator design: weight reduction improved packaging & safety Develop (a) synergistic functionalities for composite & AM; (b) design guidelines for composite-am devices. Potential use in fuel-cell tech. & automotive CPV.

19 Design for Additive Manufacturing Design for metal AM for rapid supports removal SME 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. 3D printed part (left) with support structures removed very rapidly, including inner features Design for multi-material, multi-colour parts for life-like visual effect SME Design & devt of agile electric Portable Utilitarian Vehicle (PUV) Start-up Artificial eye: Conventional manual process For illustration Pictures obtained from various sources AM-fabricated eye - Features close to actual eye, with improved accuracy Showpiece at CommunicAsia 2017 Adoption of 3D printing allows prototyping & design configuration studies to be carried out at lower cost & low-vol. runs cf. injection molding. 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. Design & fabricate exterior covers for various configurations at low-cost and high speed.

20 Multimaterial Design & AM Homogenous structure odd deflection Geometric Modeling Simulation Material Design for smooth deflection Kajima et al., 2016 Optimised composite structure UAV Composites 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)

21 Integrated Product Material Process Design Method Design Problem Formulation Multi-Objective Optimization Methods 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 Input image AM-aware Computer-Aided Design Process Structure Property Performance Encoding of microstructure using Surfacelet coefficients CAD methods enabled by geometric model Zoom-in and Zoom-out operations enabled by Surfacelet

22 New Frontiers in AM - 4D Printing - Printed Power - Soft Robotics

23 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) Complex mechanism, needs assembly, many moving parts Medical: Self deploying medical devices

24 4D printing 3D Printing + Active Materials 4D Printing Shape change with time Shape memory polymer (SMP) Ge Qi, et al

25 4D Printing DMD Toolchain & Workflow Multimaterial Polyjet printing 3D Printing Approaches Multimaterial Projection Micro Stereolithography Digital composites Material A Material B Composites (@ voxel control) Material Development 4D Printing Modeling and Simulation Thermomechanical constitutive modeling A B Formulate new materials Multiphysics Topology Optimization

26 Potential Applications of 4D Printing 4D printing enables creation of light-weight, inexpensive and simple to integrate actuating and transforming components which may find applications in Deployable structure Morphing wings *Industrial projects Self-folding/unfolding robots Potential applications of 4D printing Soft Robots Foldable Furniture Biomedical device

27 3D Printed Power LIBs Advantages for 3D printed LIBs Short ion-diffusion distance (high power density) 3D printed LIBs: Top-down technology Controlled pattern, shape. Fast prototyping. High Compatible areal-loading with density whole (high printing energy density) electronics. Short Print ion-diffusion solid electrolyte distance to (high solve safety power issue. density) Print package with special functions, such as self-healing. 3D electrodes design: 3D printed LIBs: Wang Y. et al. Advanced Energy Materials 3d-printed-graphene-battery.html 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.

28 3D Printed Power LIBs Direct Write 3D Printer Dispenser Robot Robot 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 Accomplishment: 3D Printed micro-libs Various substrates Printed Micro-LIBs: Multi layers Industry project: Freeform 3D printed batteries for microelectronics in drones Glass PET Printed single layer 6-layer, printed PDMS package

29 3D Printing of Hybrid Rocket Fuel Commercial space launch vehicles employing a proprietary hybrid rocket technology Multi-material hybrid fuel grains that are designed and 3D printed Test rocket successfully launched in Queensland, Australia in Jul D-printed fuel technology - 3.6m rocket 5km Example Thrust schedule created by designing interior propellant geometry Multimaterial printer Hybrid fuel grain Lim, et al

30 Soft Robotics Functional Materials Smart Materials / 4D Printing Large deformations in response to heat, moisture, electricity, etc. Can generate stresses required for actuation. Ge et al. Scientific Report, D 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) Scientists produce world s most stretchable 3D printable elastomer Conductive stretchable materials Highly stretchable & 3D printable electric conductors. Can provide the structure for flexible circuits and sensors unpublished Stretchable conductive circuit

31 Applications in Manufacturing New approaches to design and fabricate actuation, locomotion and sensing mechanisms in multimaterial soft systems & products Soft robotic grippers: Adaptive grippers that conform to irregular & delicate objects 1. Cable-driven high payload grippers 2. Fully 3D printed pneumaticbased grippers

32 SUTD Partnering Industry 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

33 NAMIC Introduction 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 Hub NAMIC Hub NAMIC Hub 3D printing initiative for Medical Technologies Singapore Centre for 3D Printing (SC3DP) Digital Manufacturing & Design Centre 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)

34 NAMIC Funding & Project Evaluation Process NAMIC provides matching funding up to $250K for R&D projects in AM Research Performers Industry Partners NAMIC HUB Problem Statement Definition Project Scoping, Structuring, Management and Execution Industry Capability Development Competency Creation Commercialization Planning and Support Project Evaluation and Selection Project Execution Commercialisation Industrial Implementation Commercial Product New Business Start-ups & Spinoffs Ecosystem Partners

35 Acknowledgements NRF, MOE, NAMIC, EDB, SPRING Our Partners * Our Team * * Shows examples

36 Thank You