Design for Additive Manufacturing Lab

Objective 1

Optimize the designs by exploiting the additional complexities feasible with AM (DfAM)

Challenges

  • Application of optimization techniques considering combinations of weight reduction and linear elasticity and their analogy in the thermal and electromechanical domains.
  • The ability to make designs more complex to gain an advantage of possible free complexity available with AM process
  • To overcome the cognitive barriers imposed by past experience and conventional fabrication techniques.
  • Finding the optimal distribution of material and voids in a given design space, dependent on loading and boundary conditions, such that the resulting structure meets prescribed performance targets.
Research Opportunities

  • To incorporate material, mesostructures, and multi-scale design considerations in products.
  • Incorporating the geometric and material freedoms of AM at part level with macro-scale complexity and material level with micro-scale complexity.
  • Developing internal freeform structures for improved functionality and performance.
  • Designing of macrostructure topology optimized products for reduced material and energy use.
  • Designing custom-fit products for medical, dental, and packaging industries.

Objectives

  • To cater to the need of different AM processes which require different approaches to design processes and practices.
  • To make a functionally complex product by integrating multiple functions into a single part.
  • Methodologies for Consolidating parts for reduced assembly and cost keeping in mind the AM constraints

Equipment / Software

  • AM Process Simulation Software
  • Topology optimization software 
  • Generative Design Software
  • AM Process planning software 
  • DFMA Software 
  • Open-source 3D printers 
  • Workstations 

Collaborators: GE, Autodesk, Altair, Sedaxis, Vectraform and Eaton

 

Objective 2

Digitize the product creation through Additive Manufacturing (AM)

Challenges

  • Process qualification and certification catering to medical, aerospace and defense
  • Process control and in-process measurements to reduce process defects
  • Develop new materials and novel new applications
  • Identification of suitable pre and post-processing methods to perfect the part production
  • Plan, prepare, print, and perfect complex designs by considering challenges such as material efficiency, sustainability, cost, and lead time.
Research Opportunities

  • Identification potential relationship between process-structure-property-function-behaviour relations.
  • Reducing the cost and time involved in the AM process simulation through innovative algorithms
  • Performance benchmarking of processes with respect to process capabilities of different metal AM processes
  • Hybridization of metal AM processes to optimise the buy-fly ratio of the major automotive parts

Objectives

  • To digitize the manufacturing process by adopting metal AM process and building an end-end digital implementation of the workflow
  • To create a knowledgebase of metal AM capabilities and to develop demonstrated abilities in creating application-specific solutions

Equipment / Software

  • Polymer 3D Printers 
  • Metal 3D Printer and accessories 
  • AM Process planning software 
  • Open source printers 
  • Computer Workstations

Collaborators: GE, Autodesk, Altair, Sedaxis, Vectraform and Eaton, DRDL, IIT Madras