Learn from leading experts in Additive Manufacturing on how they are finding value by designing specifically for Additive Manufacturing. Hear technical, in-depth discussions on how designers and engineers are reconfiguring their approach to problem solving through physical expression of complex geometry. Learn about design considerations, topology optimization and when to use additive manufacturing versus traditional manufacturing.
- Get direct access to AM/3DP technology and expert advice
- Hear first-hand what is working today and will work in the future
- Make new connections and build relationships with partners and peers
- Experience a dynamic mix of learning and hands-on demonstrations from industry sponsors exhibiting their capabilities
Introduction & History of Oak Ridge National Laboratory
Brian K. Post, PhD, Associate Research Staff Member, Oak Ridge National Laboratory
Development of Additive Manufactured Production Parts at Caterpillar
Paul Zwart, Additive Manufacturing Innovation & Digital, Caterpillar Inc.
Caterpillar is actively exploring opportunities to apply additive manufacturing to meet the demanding challenges of the markets we serve. This presentation will highlight one or more case studies of how this technology has been applied for metal parts, and the process of going from initial concept all the way to production parts. We will also discuss how additive manufacturing technology is enabling:
• flexibility of design to meet requirements that could not be easily met with traditional manufacturing approaches
• optimized performance of the systems where the additively manufactured parts are used
• reduced defects as compared with traditional manufacturing methods that were previously used to manufacture these types of parts
Using Additive Manufacturing to Reduce the Development Time of Racecar Parts
Brian Levy, Design Engineer, Joe Gibbs Racing
For 38 weeks a year, JGR has to prepare a total of 8 cars for that weekend’s race. Each track on the Sprint Cup Series circuit is unique and presents its own set of challenges. For instance, there are two road course circuits on the calendar that put a tremendous amount of stress on the car’s brake system. Since live telemetry is prohibited in NASCAR, the drivers must rely on the data presented on the gauges and instruments order to determine how the car is performing. In order for the driver to have the most critical information in front of him, the layout of the gauges on the car’s dashboard changes weekly. Each of JGR’s four drivers prefers a slightly different layout. To facilitate quicker changes, JGR used A.M. technologies to develop insertable dashboard pieces that can be configured an infinite number of ways and produced in less than a day so that any necessary changes are made in time for the next race. This presentation will discuss the development of these pieces and why additive manufacturing was chosen over conventional manufacturing processes. It will also explain how these parts were designed to be manufactured using FDM and Polyjet technologies.
Topology Optimization for Additive Manufacturing: Geometric and Physics-based Design Constraints
Raymond Wildman, Materials Research Engineer, US Army Research Laboratory
Structural topology optimization (TO) solutions are often too complex to manufacture, sometimes even with the flexibility of additive manufacturing (AM). For example, the selective laser sintering/selective laser melting (SLS/SLM) metal powder bed fusion process results in internal stress development in the manufactured part, which is due to the heating and subsequent cooling of the material during the build process. Owing to these stresses, the as-built part may exhibit significant shrinkage and/or warpage. To help reduce thermally activated stresses, design engineers typically add sacrificial support material to “wick away” the heat of the sintering/melting process. This support material is then removed in a labor intensive post-processing step. Therefore, it can be beneficial to incorporate AM design constraints (that consider actual part performance during the manufacturing process) directly in a TO algorithm to reduce, if not eliminate sacrificial support material. This presentation will discuss two possible approaches for generating optimized designs considering AM constraints: A purely geometric overhang angle constraint and a multiobjective solution that minimizes thermal deformation resulting from the build process. First, the overhang constraint problem can be approached using a modification of the Heaviside projection method that uses a self-support projection function with a user-defined angle. This imposes a strict constraint on overhang angles resulting in fully self-supported designs. An alternative, but more computationally costly approach is to optimize a multiobjective problem that minimizes the thermal deformation induced during the manufacturing process. The design objective is to then minimize the static compliance (computed via a standard structural mechanics solver) and the thermal deformation (computed using an AM process model or a simplified thermal contraction model) using a weighted sum of the two measures.
Design for Additive Manufacturing Applications
Evan Kuester, Applications Enginnering, 3D Systems
Value in additive manufacturing is driven by design optimization. 3D Systems will lead a technical, in-depth discussion on how designers and engineers can reconfigure their approach to problem solving through the physical expression of complex geometry. 3D Systems will provide industrial examples of how parts can be optimized and applied to real world applications.
Looking to the future, this presentation will focus on the emergent automation of this process through high frequency recursive simulation, yielding parts that allow for step changes in performance for a wide range of applications, including structural, thermal and signal amplification and absorption.
An Additive Design Revolution
Ted D. Blacker, PhD, Manager Simulation Modeling Sciences, Sandia National Laboratories
The true power of the AM revolution is not in new processes for creating materials and parts, but in the immense design freedom such manufacturing enables. We propose that a revolution in design must accompany this revolution in manufacture. Sandia National Labs is developing the PLATO tool to drive such a design revolution: a fundamentally different design paradigm using 1) newly minted topology optimization (TO) tools combined with 2) breakthroughs for designing with lattice meta-materials; overcoming the inherent and pervasive problems of existing implementations. We need a true design tool – not a toy. Of course TO designs are organic in nature, but PLATO provides shapes which are smooth, connected and directly printable – no CAD post-processing needed. The lattice design tools are enabled using homogenization for use in continuum TO, but also in the use of unique hexahedral meshing to insert the lattices conformally within the organic shapes, again print-ready – no trimming or skinning or CAD processing needed. Exploration of design uncertainty inclusion, n-materials and graded materials, residual stresses, and interactive design speeds is an integral part of PLATO.
Additive Manufacturing: How Industry is Moving From Prototype to Production
Josh Dennis, Regional Sales Manager, EOS
Breakthroughs in Large Scale 3D Printing at ORNL
Brian K. Post, PhD, Associate Research Staff Member, Oak Ridge National Laboratory
Additive manufacturing holds a lot of promise in terms of manufacturing market disruption, but there are many technical hurdles that remain before it gains wide spread adoption. Oak Ridge National Laboratory, funded by DOE’s Advanced Manufacturing Office, is targeting fundamental scientific breakthroughs in materials and processing to enable quantum jumps in performance as well as expanding the application space of the technology. This talk will highlight recent breakthroughs at ORNL in large scale 3D printing of both composites and metals which have been used to make large parts from cars to submarines to excavators. These developments enable leap changes in the scale and speed and significantly reduce the cost of production relative to conventional AM systems.
Features & Benefits of SME Membership
Ralton Emory, Member and Industry Relations Manager, SME
Guided Plant Tour – Oak Ridge National Laboratory, Manufacturing Demonstration Facility
Read More Major emphasis on large scale polymer composite printers, large-scale metal printers, powder bed systems, and IACMI composites lab.
As attendees walk through the high bay they will be able to see how the MDF works with industry, other R&D institutes, and other parts of ORNL in order to achieve:
Major emphasis on large scale polymer composite printers, large-scale metal printers, powder bed systems, and IACMI composites lab.
Who Should Attend?
Manufacturing engineers, manufacturing owners & presidents, technical managers, product managers, mechanical engineers, applications engineers, research & development, academia, and others interested in additive manufacturing technologies to streamline design and production, reduce time to market, and build more efficient parts, products, and operations.
What Will Be Covered?
- Additive manufacturing
- 3D Scanning & Imaging
- RAPID prototyping
- Measurement and quality
- Advanced additive materials
- Additive manufacturing applications
- And more
|Pricing||SME Members||Non-Members||Academia Government/Military*
(15% discount as shown below)
Member / Non-Member
(50% discount as shown below)
Member / Non-Member
|Seminar||$595||$695||$505.75 / $590.75||$297.50 / $347.50|
*Academic, Military & Government Pricing: To qualify for the reduced rate you must submit a letter on appropriate military/government letterhead signed by your Commanding Officer or supervisor to the SME Registrar. Educators may submit either a letter on university letterhead signed by the dean or registrar confirming status or a class schedule inclusive of the institution/year/instructor.
**Full-Time Students: To qualify for student rates, submit a letter on university letterhead signed by the dean or registrar confirming full-time student status or provide a copy of your student I.D. to the SME Registrar.
Interested in sponsoring or speaking at the event? Contact Carl Mitroff at firstname.lastname@example.org or 313.425.3157
Oak Ridge National Laboratory
National Transportation Research Center
2360 Cherahala Blvd
Knoxville, TN 37932