Methodology for Biomimetic Design of Additively Manufactured Structural Components
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Beschreibung
This thesis tackles a key challenge in lightweight design: developing detailed methods to create biomimetic designs based on topology optimization and produced by metal additive manufacturing. To address this, a novel five-step methodology was developed. Starting from an abstracted 3D model of cylindrical beams and spherical nodes derived via skeletonization, the approach applies finite element analysis to assess internal forces and moments. It then optimizes design parameters for two biomimetic and two conventional beam types across various load cases, selecting the lightest beam design for each case. Structural integrity is ensured through buckling analysis and re-dimensioning of beams. Nodes are adapted with lattice infill, maintaining powder removability while reducing weight. The final biomimetic components undergo validation via finite element analysis, with their mass compared against the original designs. Validated on three standard topology optimization problems, the method revealed localized high-stress regions and achieved significant weight reductions of 12.5% to 30.3%. Unlike previous approaches, it uniquely integrates internal force and moment evaluation for precise dimensioning of biomimetic beams, closing a gap in biomimetic design methodologies. This work advances the field of biomimetic lightweight design for industries such as aerospace and automotive, promoting more efficient and manufacturable components.
The Author:
Tim Röver (born 1992) earned his M.Sc. at Hamburg University of Technology (TUHH), where he conducted his PhD research. His work focuses on additive manufacturing, topology optimization, biomimetics, and numerical methods for mechanical and thermal component optimization. He held visiting researcher positions at Fraunhofer IAPT (Hamburg) and Mondragon University (Spain). At TUHH, Röver led a research group and currently serves as Head of Innovation in industry. He has co-authored over 16 peer-reviewed publications.
Previous research indicates that incorporating biomimetic beam‑like structures into topology optimization designs can enhance the lightweight characteristics of components such as aviation brackets that were produced by the additive manufacturing technique of powder bed fusion of metal with a laser beam. However, there is a need for detailed design methodologies to effectively implement such design modifications. The first research question of this thesis explores how a design methodology can be developed to generate biomimetic design components from density‑based topology optimization designs. The secondary research question assesses the lightweight characteristics of the outcomes generated by such a methodology, comparing them to those of the input topology optimization design. A five‑step design methodology with detailed submethodologies was developed. It takes a topology optimization design as an input and, in the first step generates an auxiliary 3D model consisting of cylindrical beams and spherical nodes that resembles the topology optimization design. A skeletonization approach is used for abstraction. In the second step, a finite element analysis of the auxiliary model is performed to evaluate the internal forces and moments in its beams. In step three, two biomimetic parametric beam designs as well as two conventional parametric beam designs are considered for parameter optimization for each of the beam load cases from the auxiliary model. The most lightweight optimized beam is selected for each of the beams of the abstraction, respectively. Buckling analyses and re‑dimensioning of optimized beams are performed, if necessary. In step four, adapted nodes for the biomimetic component design are generated. The nodes contain a lattice infill structure to ensure powder‑removability and a lightweight design. In step five, the complete biomimetic component design is validated by finite element analysis and the mass of the component is evaluated. Thus, a complete design methodology was developed successfully. Three common topology optimization problem formulations were considered for validation of the developed biomimetic design methodology. Finite element analyses of the biomimetic designs yielded the existence of critical regions of high stress in all three of the biomimetic components. However, the locations of critical stresses have been associated with specific regions within the biomimetic designs. Mass evaluation showed that the biomimetic component designs are 12.5 % - 30.3 % lighter compared to their topology optimization counterparts. The developed methodology stands out from previously existing research as it considers the internal forces and moments in beams and closes a research gap for detailed design methodologies for biomimetic structural components. This thesis contributes to harnessing the immense potential of biomimetic design in lightweight industries, such as aerospace and automotive. Future research should refine the presented methodology and perform experimental assessment of component designs generated by it.
Proposes a biomimetic design methodology to complement topology optimization in lightweight structural design Integrates additive manufacturing with topology and parameter optimization and biomimetics for manufacturable parts Indicates high potential for additional weight savings beyond topology optimization in aerospace and automotive
Autor*in
Tim Röver
Themen in »Methodology for Biomimetic Design of Additively Manufactured Structural Components«
Lightweight Design Design for Additive Manufacturing (DfAM) Additive Manufacturing (AM) Powder Bed Fusion of Metal with Laser Beam (PBF-LB/M) Selective Laser Melting (SLM) Mechanical Design Generative Design Computational Design Structural Optimization Design Optimization Topology Optimization Parameter Optimization Size Optimization Biomimetics Bionics