Posted to News on 19th Dec 2018, 15:12
Renishaw improves access to efficient metal 3D printed parts
Renishaw is working with autonomous topology optimisation expert ParaMatters to give manufacturers access to efficiently manufactured metal 3D printed parts. ParaMatters' easy-to-use CogniCAD cloud offering enables users to upload part geometries for optimisation; CogniCAD automatically produces lightweight macro, meso and lattice structures using generative design principles, backed up with high-resolution finite element analysis (FEA) validation. CogniCAD users are no longer constrained by traditional complex CAD/CAE/CAM tools because all they need to do is upload their part and follow the intuitive CogniCAD workflow and simple interface to prepare a 3D printable model.
Renishaw has previously used CogniCAD to reduce the weight of the upper mounting bracket for ECOSSE Moto Works' motorcycle, the Nightstalker (see photo). Lightweight components are important in motorcycles for ensuring fuel efficiency and improved dynamics. Here, the two complementary technologies are used together to produce lightweight and structurally robust components and Renishaw's collaboration with ParaMatters has made both technologies accessible to its customers.
Michael Bogomolny, Co-Founder & CTO of ParaMatters, explains: "We worked with Renishaw to establish a smooth workflow that made it possible to automate the entire process from design to manufacturing. CogniCAD uses topology optimisation, computational geometry and high-performance computing to autonomously generate designs that are adapted to make the best use of AM."
ParaMatters produced a design for the motorcycle bracket that included a lattice structure to reduce the weight. Once redesigned, the bracket's structural performance was validated using FEA, provided by CogniCAD, and assessed by fitting it onto the motorcycle. The results exceeded expectations. The final bracket was 35 per cent lighter than the original part, the maximum stress was 20 per cent less and the fundamental natural frequency of the part was two per cent greater.
'Click to Print'
In a new extension of the collaboration, Renishaw will use CogniCAD at its AM Solutions Center in West Dundee, Chicago, USA. ParaMatters will join Renishaw's network of software vendors and will provide 'Click to Print' functionality from CogniCAD. This will enable design review and printability assessment by Renishaw experts before additive manufacture commences. ParaMatters will also have access to Renishaw additive manufacturing (AM) systems for joint customer projects.
Stephen Anderson, AM Business Development Manager at Renishaw Inc, explains: "Generative design has a clear role to play in lightweighting parts that cannot be produced by computer numerical control (CNC) machining alone. However, for many manufacturers, the initial investment required to perform such optimisations is too high. By working with ParaMatters potential users can easily try topology optimisation, see the results and then engage with Renishaw to assess final suitability for additive manufacturing."
Bogomolny comments: "We successfully use Renishaw to additively manufacture ParaMatters' optimised designs and have been really impressed with the results. We have developed CogniCAD, Meta-Materials Compiler and our new Unique Meso-Structural Designer, that can be used to develop realistic bone-like structural implants - all with simple web-based GUIs allowing for the fast creation of optimal, FEA checked, components. We believe working with Renishaw and implementing 'Click to Print' in our offering will help open up ever wider markets for metal additive manufacturing and our software."
Follow the link for more information about Renishaw's AM systems and applications.
