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Fabrication Process

Harvard Wyss Institute

Harvard Wyss Institute:

A nozzle moves along a preset path sending out a thin stream of silver nanoparticles, while at the same time a laser follows its progress, heating the particles and solidifying them into a freestanding filament thinner than a human hair.

 

http://wyss.harvard.edu/viewpressrelease/257

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Fabrication Process

Arc Bicycle: 3D printed steel bike

In a three-month project a bicycle frame has been designed by team of students from the Netherlands’ Delft University of Technology to showcase the potential of the printing specialists MX3D of Amsterdam and their method of printing metal by three-dimensional means. Development of the ‘Arc Bicycle’ is part of a research project at AMS Building Fieldlab, and involved use of multi-axis robotic arms to 3D-print the frame. As Harry Anderson of the design team states, “The topic of 3D printing has exploded in popularity over the last decade, but the technology still comes with significant limitations for those wanting to print medium- to large-scale objects. The MX3D method of 3D printing now makes it possible to create large metal objects with almost total form freedom”.

 

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Software

Autodesk Within

Within generative design software solutions help engineers and orthopedic implant specialists produce lightweight, latticed designs that are functionally optimized and accurate for additive manufacturing.

http://www.autodesk.com/products/within/overview

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Fabrication Process

VOXELJET – TOPOLOGY OPTIMIZATION LEADS TO A PRIZE-WINNING CAST PART

The project began with the need to significantly increase the rigidity of the Wheel Upright without changing the weight or materials used. With the help of cutting-edge simulation tools and using the full range of structural design freedom offered by 3D printing technology, the partners produced a Wheel Upright that is up to five times more rigid than its predecessor. Kevin Smith, Sales Director with voxeljet UK, describes the benefits as follows: “The design freedom of additive manufacturing processes, combined with simulation, allows us to come up with a new generation of designs that overcome the earlier conventional design limitations.” It was voxeljet’s 3D printing process that made it possible to implement cast part geometries with this level of complexity. “Because of this, the CMF jurors had a hard time at first believing that this complex Wheel Upright was an aluminum investment-cast part,” Smith adds. This project is an impressive demonstration of the potential that exists with regard to boosting performance and/or reducing weight.

http://www.foundry-planet.com/news/corporate-news/detail-view/voxeljet-topology-optimization-leads-to-a-prize-winning-cast-part/

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Fabrication Process

Janne Kyttanen’s 3D printed sofa design weighs just 2.5 kg but can hold up to 100 kg

When it comes to deciphering the possible usage of new technologies – additive manufacturing technologies especially – oftentimes the creators of the technology themselves will hire some of the top creatives in their field to test the limits of what’s possible with the new technology – whether it’s for the development of a new piece of hardware or for a new software application.  Oftentimes, the result is nothing short of remarkable.

Such is the case more recently with 3D printing pioneer Janne Kyttanen, a designer who is currently a senior creative fellow at 3D systems responsible for churning out creative applications for the company’s latest tech.  Kyttanen’s latest piece, Sofa So Good, was inspired by the structures of spiderwebs and silkworm cocoons to create a sofa design that could only be fabricated using additive manufacturing technologies.

http://www.3ders.org/articles/20150603-janne-kyttanen-3d-printed-sofa-design-weighs-can-hold-up-to-100-kg.html

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Fabrication Process

Topology optimisation of material microstructure

This project is aimed at establishing effective and efficient computational algorithms for optimising the microstructures of materials and composites with single or multiple functional properties.

New and advanced materials are of critical importance to the aerospace, automotive, medical and other industries.

Using the simple BESO technique, we have successfully developed optimisation algorithms for the topological design of cellular and composite materials considering a wide range of design objectives, including maximising bulk modulus, maximising shear modulus, maximising thermal conductivity, maximising magnetic permeability, maximising electrical permittivity, and maximising or minimising a combination of these properties. We have also used the same technique to design microstructures for functionally graded materials, and for orthotropic materials with prescribed ratios between effective stiffnesses in three directions.

https://www.rmit.edu.au/research/research-institutes-centres-and-groups/research-centres/centre-for-innovative-structures-and-materials/projects/topology-optimisation-of-material-microstructure/

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Fabrication Process

Electron Beam Welders & Custom EB Welding Solutions

Electron Beam (EB) Welding is an excellent choice for applications containing refractory alloys and dissimilar materials. Advantages of EB Welding technology include a high power density with very low overall heat input and, therefore, minimum distortion. EB welded parts require a minimum of post-weld machining and heat treatment, and, unlike other fusion welding processes, EB requires no shielding gases. The weld quality is exceptional and the process is extremely efficient (typically 95%), carefully controlled and fully automated.

http://www.sciaky.com/eb-welding-systems/electron-beam-welding-solutions

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Fabrication Process

http://www.sial.rmit.edu.au/portfolio/smartnodes/

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Design Study

SmartNodes

SmartNodes is a research project that is part of the Independents’ Group (IG) of which Kristof Crolla received the first Fellowship in 2013. The research project is hosted at RMIT University, Melbourne, in collaboration with industry partner Arup, and explores the potential for pairing unique, high-tech, weight optimal node components with off-the-shelf, standard beams and fixings to accomplish customized and complex building form. It addresses the challenge of designing and prototyping a lightweight canopy structure. The system is underpinned by a series of custom manufactured structural nodes, designed and optimized with digital algorithms and produced using the latest 3D metal printing technology. These link simple beams and planar panels. Through the customized geometry of each node, the system has the potential for a broad range of design outcomes without significant cost penalties.

The Laboratory for Explorative Architecture & Design (LEAD) is a young Hong Kong & Antwerp based architectural design and research practice founded by Belgian architect Kristof Crolla