THIS PROPOSAL TITLED TOPOLOGY OPTIMIZATION FOR ADDITIVELY MANUFACTURED STRUCTURES ACCOUNTING FOR MATERIAL VARIABILITY AND FLAWS SEEKS TO ADDRESS THE UNCERTAINTIES THAT ARISE WHEN DESIGNING COMPONENTS AND STRUCTURES TO BE PRODUCED THROUGH THE ADDITIVE MANUFACTURING (AM) PROCESS. THESE UNCERTAINTIES CAN BE CAUSED BY THE VARIATIONS OF MATERIAL PROPERTIES THROUGHOUT AN AM BUILD GEOMETRIC CONSTRAINTS SUCH AS OVERHANG ANGLES WHICH MAY DEFORM THE STRUCTURE DURING FABRICATION UNCERTAINTY IN LOADING SCENARIOS AND INCORRECT DEPOSITION. TO ADDRESS THESE ISSUES THE PROPOSAL DISCUSSES THE USE OF TOPOLOGY OPTIMIZATION (TO) USING GRADIENT-BASED OPTIMIZERS TO DESIGN COMPONENTS WHICH SPECIFICALLY ADHERE TO THESE CONSTRAINTS AND UNCERTAINTIES IMPOSED BY THE AM PROCESS. THE INITIAL IMPLEMENTATION OF MANUFACTURING CONSTRAINT SUCH AS MINIMUM FEATURE SIZES AND OVERHANG ANGLES WILL DIRECTLY CONNECT THE DESIGN SPACE TO THE FABRICATION PROCESS WHICH CAN THEN BE USED TO CONTROL HOW THE OPTIMIZER DESIGNS THE STRUCTURE. USING THESE METHODS THAT DIRECTLY RELATE TO TO AM FORMULATIONS FOR IMPERFECTIONS OR MATERIAL ANISOTROPIES CAN BE ADDRESSED IN THE DESIGN ALGORITHM AND OTHER TECHNIQUES SUCH AS UNCERTAINTY QUANTIFICATION CAN BE LEVERAGED TO PROVIDE A ROBUST METHODOLOGY ACCOUNTING FOR VARIATIONS. THROUGH THE USE OF PARALLELIZATION AND METHODS FOR HIGH PERFORMANCE COMPUTING ADAPTIVE ALGORITHMS WILL BE DEVELOPED TO REDESIGN AND ADAPT SOLUTIONS WHICH DEVELOP FLAWS DURING THE MANUFACTURING PROCESS. SUCH AN ALGORITHM WOULD ELIMINATE THE NEED FOR EXPENSIVE ITERATIVE TESTING USED TO DEVELOP STATISTICAL PROPERTIES OF COMPONENT-WISE FABRICATIONS. THESE MODIFICATIONS TO THE DESIGN AND MANUFACTURING PROCESSES COULD DRAMATICALLY REDUCE THE COST OF PRODUCTION AND EVALUATION OF STRUCTURAL COMPONENTS USED IN SPACECRAFT AND THE MATERIAL USED IN EACH COMPONENT WHICH IN TURN COULD YIELD SIGNIFICANTLY LIGHT WEIGHTING OF COMPONENTS WITH LARGE FUEL SAVINGS.
$282,420FY2020National Aeronautics and Space AdministrationNASA
The Johns Hopkins University