"Porous structure design is used in engineering to create lightweight materials with exceptional characteristics like high mechanical strength-to-weight ratios. These structures feature interconnected voids or pores, which reduce overall weight without compromising strength, making them ideal for applications where weight and energy consumption is a concern, such as the aerospace and automotive industries. Additive manufacturing has emerged as the go-to method for producing such intricate structures because it allows for precise control over the internal architecture, enabling the creation of complex geometries that are challenging or impossible to achieve with traditional manufacturing methods. However, transitioning from design to 3D printing poses itschallenges, and ensuring the fidelity of the final printed product requires careful consideration of factors like material properties and printing parameters."-- Provided by publisher.
Concise, practical guide presenting skills to integrate porous structure design with additive manufacturing requirements
Part of Wiley's Additive Manufacturing Skills in Practice series and written with the industry practitioner in mind, Advanced Techniques in Porous Structure Design for Additive Manufacturing addresses the growing integration of porous structures and additive manufacturing, essential for applications in the biomedical, aerospace, and automotive fields in which porous structures are crucial due to their ability to deliver top-notch performance alongside lightweight characteristics.
This book covers all areas of the subject and concludes with a series of specialized chapters devoted to simulation software, case studies, and future trends and emerging technologies. Each chapter features a design problem that presents an open-ended scenario to prompt readers to think through the real-world applications of the concepts and theories discussed and connect them to their own job roles.
Sample topics discussed in Advanced Techniques in Porous Structure Design for Additive Manufacturing include:
- Fundamentals of additive manufacturing, covering processes, materials, and design considerations
- Mathematical modeling, covering optimization techniques and the finite element method
- Multiscale topology optimization, shape optimization methods, and post-processing techniques
- Software utilization in porous structure design, with information on how to program simulations
- Porous structures in soft robotics, porous heat sinks, porous plates, and porous mechanical support structures
With a blend of theoretical understanding and hands-on expertise in an emerging domain, Advanced Techniques in Porous Structure Design for Additive Manufacturing is an essential reference for industry professionals, researchers, and postgraduate students in universities, particularly those specializing in mechanical design and additive manufacturing.
Preface ix
Chapter 1 Introduction to Porous Structures and Additive Manufacturing 1
1.1 Introduction 1
1.2 Why Designing Porous Structures 6
1.3 Types of Cells 8
1.4 Challenges in the Design and Fabrication of Porous Structures 10
References 12
Chapter 2 Fundamentals of Additive Manufacturing 15
2.1 Introduction 15
2.2 Metallic Materials 16
2.3 Metallic Additive Manufacturing 20
2.4 Plastics 24
2.5 Plastic 3D Printing 26
2.6 Ceramics 28
2.7 Ceramic 3D Printing 29
2.8 The Production Cycle of 3D Printing 31
2.9 Challenges Facing Additive Manufacturing 34
2.10 Emerging Techniques in Additive Manufacturing 38
References 41
Chapter 3 Mathematical Modeling for the Calculation of Porous Structure
Properties: Techniques and Applications 43
3.1 Introduction 43
3.2 Overview of Computational Assessments of Physical Properties of
Materials 44
3.3 Mechanical Properties of Microstructure 47
3.4 Effective Elasticity Tensor for Porous Structures using FEM Formulation
57
References 63
Chapter 4 Advanced Techniques in Porous Structure Design 65
4.1 Introduction 65
4.2 Parametric Optimization 69
4.3 Non-Parametric Optimization 72
4.4 Multiphysics Topology Optimization Fundamentals 76
4.5 Topology Optimization Methodologies 81
4.6 Shape Optimization 86
4.7 Porous Structural Design 91
References 97
Chapter 5 Practical Examples and Case Studies 103
5.1 Introduction 103
5.2 Porous Heat Sink Designs with Non-Parametric Optimization 103
5.3 Application of Robotics 128
References 165
Chapter 6 Advanced Software Utilization for Designing and Analyzing Porous
Structures 173
6.1 Introduction 173
6.2 Commercial Software 174
6.3 Coding-Based Commercial Software Design of Porous Structures 176
References 192
Chapter 7 Emerging Trends and Directions in Advanced Porous Structures 195
7.1 Introduction 195
7.2 Advanced Manufacturing 196
7.3 Applications of Advanced Porous Structures 197
7.4 Challenges and Future Directions 201
References 202
Index 207
Musaddiq Al Ali, PhD, is a research scientist at the Toyota Technological Institute, where his work on additive manufacturing methods for the creation of multifunctional, ultra-lightweight structures for smart vehicles is sponsored by the Toyota Corp. His career has included teaching undergraduate and postgraduate courses in mechanics, heat transfer, fluid dynamics, numerical methods, manufacturing processes, control systems, dynamics, computer-aided design, and mathematical programming.
