Sports Article Parameter Optimization for Faster Additive Manufacturing
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Solution Overview
Problem
The design process of sports articles, particularly those using additive manufacturing, is hindered by the complexity and time-consuming nature of simulations required to optimize numerous physical parameters, such as those related to elasticity, stiffness, and material properties, which increases production costs and time.
Innovation Solution
A method that splits physical parameters into two groups: a first group set by the designer for basic properties and a second group optimized to achieve specific objectives, using an iterative process combining heuristic and finite element analysis evaluations to reduce the number of variables and simulation time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If extensive simulations using finite element methods are performed to optimize physical parameters, then the quality and performance of the sports article is improved, but the design time and computational cost increase significantly
Solution Approach 1:
The patent segments the design process into two distinct phases: a first phase using fast heuristic algorithms to explore the design space and identify promising regions, and a second phase using accurate but time-consuming finite element simulations to precisely optimize only those specific parameters identified in phase one. This segmentation allows the system to maintain high optimization quality while dramatically reducing total computational time.
Solution Approach 2:
The patent performs preliminary optimization using heuristic algorithms before conducting the final finite element analysis. This preliminary action identifies the most promising parameter combinations and design regions, allowing subsequent detailed simulations to focus only on these targeted areas rather than exhaustively searching the entire parameter space, thereby reducing overall design time.
2Manufacturing precision
If the number of physical parameters to be optimized is increased to account for additive manufacturing complexities, then the comprehensiveness of the design optimization is improved, but the complexity and run-time of simulations increase
Solution Approach 1:
The patent divides parameters into two groups: those optimized by fast heuristics and those requiring detailed FEM analysis. This segmentation allows comprehensive parameter optimization while managing simulation complexity by applying appropriate methods to each parameter group.
Solution Approach 2:
The patent introduces heuristic algorithms as an intermediary between the design parameters and the finite element simulations. These heuristics serve as a mediator that pre-processes the parameter space, identifies promising regions, and guides the subsequent FEM analysis, thereby reducing the overall complexity of the optimization process.
3Weight of moving object
If multiple beam parameters are optimized to reduce material and weight, then the efficiency of the sports article is improved, but the number of parameters to be fixed increases significantly
Solution Approach 1:
The patent segments beam parameters into categories that can be optimized by heuristics versus those requiring FEM analysis. This allows efficient optimization of multiple beam parameters for weight reduction while managing the complexity of the large number of parameters through hierarchical optimization strategies.
Data Source
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AI summary
The present invention relates to a method of manufacturing at least a part of a sports article, comprising the steps: (a.) determining a set of physical parameters of the sports article, the set comprising a first group and a second group; (b.) determining a set of constraints for the first group of the physical parameters, wherein the set of constraints is intended to achieve at least one objective function; (c.) determining an optimum for the at least one objective function, wherein the optimum is determined by optimizing the second group of physical parameters; and (d.) manufacturing the part of the sports article according to the set of constraints and the second group of optimal physical parameters.