Generative Shell Structures for Crash Simulation and Additive Builds
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current generative design methods for crash simulations result in heavy, stiff solid state designs that are computationally expensive and unwieldy, lacking an efficient mechanism for producing better-performing lightweight designs suitable for both additive manufacturing and CAE crash simulations.
Innovation Solution
A lightweight shelled generative design with internal support structures is developed, allowing for efficient simulation and validation, utilizing a workflow that integrates CAD and CAE models, reducing the number of mesh elements significantly and avoiding re-coater interference and powder trapping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a solid state generative design is used for crash simulation, then the design provides structural strength and stiffness, but the design becomes heavy and computationally expensive with approximately 1,500,000 mesh elements
Solution Approach 1:
The patent applies shell elements to represent the generative design geometry instead of solid elements. This transforms the modeling approach from volumetric solid state design to surface-based shell design, dramatically reducing mesh element count from 1,500,000 to approximately 15,681 elements while maintaining structural strength and stiffness properties needed for crash simulation accuracy.
2Strength
If a solid state generative design is used for crash simulation, then the design provides structural integrity, but the simulation processing time becomes excessively long due to the large number of mesh elements
Solution Approach 1:
The patent utilizes shell elements that require significantly fewer mesh elements to represent the same geometry compared to solid elements. This reduction from 1,500,000 to 15,681 elements directly decreases computational burden and simulation processing time while preserving the structural integrity needed for accurate crash simulation results.
3Weight of moving object
If a shelled generative design with internal support structure is used for additive manufacturing, then the design achieves weight reduction and avoids powder trapping, but the design complexity increases
Solution Approach 1:
The patent employs shell elements with internal support structures that are optimized for additive manufacturing. The shell geometry inherently avoids enclosed cavities that would trap powder during the additive manufacturing process, while internal support structures provide necessary structural reinforcement. This approach achieves 70% weight reduction compared to solid state designs while maintaining manufacturability.
4Productivity
If a shelled generative design is used for both additive build simulation and crash simulation, then the design enables efficient simulation with reduced mesh elements, but the design may create re-coater interference in additive manufacturing
Solution Approach 1:
The patent designs shelled geometries that are compatible with both crash simulation and additive manufacturing processes. The shell structure with optimized wall thicknesses and internal support placement ensures that the design can be efficiently simulated with reduced mesh elements while avoiding features that would cause re-coater interference during additive manufacturing, such as overly thin walls or complex internal cavities.
Data Source
AI summary
A method and system provide the ability to generate models. A generative shelled base is created as a hollow computer-aided design (CAD) design. A t-spline mid-surface shell is created from the generative shelled base, which is then used to create a shell mesh model. A t-spline solid body is created from the generative shelled base, which is used to create an internal support structure that is converted into a shell CAD geometry, which is used to create a support structure mid-surface shell. The support structure mid-surface shell is combined with the shell mesh model into a generative mid-surface mesh that is used in a computer-aided engineering (CAE) crash simulation. The generated shelled base is combined with the shell CAD geometry into a generative shelled solid that is utilized in an additive build simulation.