Digital Manufacturing and Design Workflows to Enable

New Product Innovations

Lim Keng Hui Director, DManD & NAMIC@SUTD Kenghui_lim@sutd.edu.sg

Content

• Introduction to SUTD

• Digital Manufacturing & Design Centre (DManD) – Overview

– Advances in AM / 3D printing

• NAMIC and Industry Partnerships

2

A Better World by Design: Educating Technically-grounded Leaders and

Innovators for the 21th Century

An Outside-In Curriculum

Design projects Electives

Architecture &

Sustainable

Design

Engineering

Product

Development

Engineering

Systems &

Design

Information

Systems

Technology &

Design

Senior

Junior

Sophomore

Freshmore

Capstone: Integrated Design Experience

• Four 12-unit subjects per semester ( x 8 semesters) 22% humanities courses

Statistical Reasoning and Optimization

Archi- tecture

Core

Product Design Core

System Design Core

Info Design Core

Entrepreneurship, Management, Social Science, Economics, Humanities, Arts

Energy & Structures

Dynamics & Control

Linear Signals & Systems

Information, Computation, Materials and Systems

FOUNDATIONS Mathematics, Science, Introductory Humanities, Social Sciences

in the context of Design

Digital World Physical World Systems World

Active and Collaborative Learning

• Student-faculty ratio of 11:1

• Integrating lectures, recitations and design projects (Learn, Engage and Apply)

• Group learning & peer support

• Ready access to fabrication equipment

Digital Manufacturing & Design Centre (DManD)

DManD Positioning

Vision for Digital Manufacturing

v. 1.0

Advance frontiers in design and manufacturing enabled by the digital thread that integrates the product innovation and development value chain.

Approaches to Design & Manufacturing

Design Innovation

Materials Selection

Manufacturing Method

• Mostly sequential process • Few interactions • Limits design freedom

• Non-sequential process • Creates interactions • New degrees of freedom • Expands design freedom & facilitates innovation

Old Design dictates materials and manufacturing selection

New Manufacturing and materials differentiate product design

Ref from IRI Keynote, Nov 2011

Design Innovation

Materials Innovation

Manufacturing Innovation

Digital Workflows

DManD Research

Geometry Composition Performance & Function

Stratasys, 2015 Multimaterial joint

Kaijima, SUTD

Soft robot

Alvarado, SUTD

Rocket fuel

Gilmour, SUTD

3D printed battery

Yang, SUTD

✔ ✔ ✔

Geometry & Information Acquisition

Computational Engineering

Digital Fabrication & Assembly

Digital Design

Computational Manufacturing

Testing and Characterization Materials

Digital workflows that integrate Design – Materials – Manufacturing Innovations to accelerate next-gen product development

High-res multimaterial 3D printing

4D Printing: smart actuating materials

! ! !

! 29!

As!an!extension!of!our!topology!optimization!approaches!in!Thrust!1.2,!we!will!develop!an! approach! to! design! the! optimum! layout! of! fibers! in! a! composite! in! 2D!lamina/laminates! as!well! as! general! 3D! solids.! !One! approach!we!will! pursue! is:! i)!mathematical!homogenization!to!describe!an!anisotropic!composite!as!an!anisotropic!solid!at!the!level!of!a!3D!voxel,! ii)!a!topology!optimization!(Thrust!1.2)!approach!to!determine! the! optimal! stiffness! tensor! (or! orientation@dependent! property),! iii)! a!computer!graphics!approach!similar!to!that!used!in!diffusion!tensor!imagining!of!tissue!to! then! create! physical! fiber! and! fiber! bundle! realizations! from! the! optimal!homogenized!solution,!and! then! iv)!middleware! to!print!using!our! technology! to!be!developed.!!Preliminary!efforts!are!shown!in!Fig.!7;!while!the!representation!is!visually!descriptive,!it!can!not!be!realized!physically!and!our!efforts!here!will!make!this!possible.!!

!!Fig.!7!Preliminary!a!homogenization@based! topology!optimization!approach! to!determine! the!optimal!anisotropic!stiffness!distribution!of!a!component!at!the!voxel!scale!and!then!generate!fiber!bundles!with!a!spatially@varying!volume!fraction!f!that!can!be!printed!is!shown!in!Fig.!7.!!We!will!pursue!a!second!approach!for!individual!fibers!that!may!be!structural!or!more!importantly!functional,!e.g.,!electrical.!!Here!we!will!represent!fibers!as!nonlinear!elastic!and! form!mathematical! optimization! problems! to! determine! optimal! layouts! in! 3D!space!consistent!with!compatibility!with!a!possibly@deforming!3D!printed!solid.!!!Our!efforts!will!focus!on!structural!fibers!to!begin,!e.g.,!glass,!carbon,!and!aramid,!but!we!will!then.!!We!plan!to!pursue!Aracon!metal@coated!aramid!fibers!to!create!integrated!structural!composites!with!integrated!electrical!wiring!within!complex!3D!geometries.!!Recent!investments!in!these!fibers!is!rapidly!bringing!the!cost!down!so!that!they!are!likely!to!emerge!as!next@generation!manufacturing!staples.

!Exploitable Outcomes:!New!capabilities!that!will!allow!transition!of!existing!printed!plastics!to!robust!structural!materials,!optimized!light@weight!structures!for!products,!and! complex! 3D! multifunctional! structures;! technology! that! allows! increased!integration!of!prototyping!with!final!manufacturing!by!being!able!to!prototype!in!plastic!and! then! immediately! manufacture! with! carbon! fiber;! technology! to! manufacture!!integrated! structures! with! multifunctional! fibers! for! sensing,! actuation,!communications,! etc.,! new! joining! methodologies! for! composites! enabled! by! direct!printing!of! fiber!composite;!design!software!for!optimal! fiber!placement!that!can!be!used!with!existing!robotic!fiber!laying!machines.!!!!!!

Design & optimization: mechanical, thermal, fluidics, aesthetics

3D printed batteries, sensors & electronics

Easy to use software tools for complex design

Nano-mfg of functional surfaces, e.g. color, self cleaning

Soft Engineering & Robotics

Digitized textured surfaces

3D Composites & Textiles

Generative design Design for Additive Mfg

3D scanning & automated reconstruction with AI & VR/AR

Robotics & hybrid processes

DesignInnova on

MaterialsInnova on

ManufacturingInnova on

DigitalWorkflows

Additive Manufacturing Value Propositions

1. Accelerating product development

2. Reducing cost for HMLV manufacturing

3. Exploiting design freedom

4. Developing new applications

5. Simplifying supply chain, reducing lead times

Source: PADT, Inc

Value Propositions

1. Accelerating product development 2. Simplifying supply chain, reducing lead times & inventory 3. Reducing cost for HMLV manufacturing

Product Development process showing the role of prototypes (most often 3D printed) Assembly consolidation

(e.g. Fuel assembly system with reduced number of parts; Embedded electronic products)

Value Propositions

4. Exploiting design freedom

Complex design, internal features, reduced part numbers (e.g. ultra-strong & light materials; exhaust gas probe with complex features)

Strength-to-weight optimisation (e.g. brackets)

Multi-material, multi-functional manufacturing (e.g. 3D printed electronics embedded, advanced composite structures)

Bio-inspiration (e.g. leveraging lattice designs, functional nano-surfaces)

Value Propositions

5. Developing new applications

Soft robots and customised smart products

Smart objects via functional & multimaterial printing, e.g. self assembly, shape changing products

Zoomorphic Design

• Noah Duncan, Lap-Fai Yu, Sai-Kit Yeung,

Demetri Terzopoulos

• First computational Approach in Designing

Zoomorphic Shape

Rapid and easy-to-use design tools, e.g. personalised products

3D printed UAV

AM @ DManD

Additive Manufacturing @ DManD

DMD

UV

Continuous Fiber Composite Printing MarkForge M1

Inkjet Printing

Direct Metal Laser Sintering (DMLS) EOSINT M280

Fused Deposition Modeling Printing Stratasys Fortus 450mc

Polyjet Printing, Multimaterial, Full Color Stratasys J750

Aerosol Jet Electronics 3D Printing

Two-Photon Photopolymerisation Nanoscribe

Multimaterial Projection Micro Stereolithography (MPµSL)

In-house developed, example:

Multimaterial Rocket Fuel Grain Printing

Polymer Metal Fiber Composite Electronics & Ink

Other printing technologies, e.g. SLA

Polymer Fibre-Reinforced Laser-Sintering EOS P396

Multijet Fusion HP

• Design for Additive Manufacturing

• Additive Manufacturing Processes

0 10 20 30 40 0 5 10 15 20 25 30 35 40 45 50

1

2

39.6 39.74 39.42 41.1

41.3

41.5

Design for Additive Manufacturing

Rosen, D. R.

Design for Additive Manufacturing

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Standards for Design Rules for AM

• Develop international standards (ISO & ASTM) for Design rules for AM, including design principles and design for powder bed fusion, SLA and FDM ☞ Promote adoption of AM through propagation of design standards for AM

Design for AM of integrated pressure regulator for composite pressure vessel

• Develop (a) synergistic functionalities for composite & AM; (b) design guidelines for composite-AM devices.

☞ Potential use in fuel-cell tech. & automotive CPV.

Current carbon fiber-reinforced composite pressure vessel designs with protruding pressure regulator

Integrated pressure regulator design: ▶ weight reduction ▶ improved packaging & safety

SME

Design for metal AM for rapid supports removal SME

3D printed part (left) with support structures removed very rapidly, including inner features

• Develop easy-to-remove support structure design & removal process for metal 3D printing. ☞ Improve efficiency & cost-effectiveness of metal printing by minimising post-processing effort.

Design for Additive Manufacturing

Design & devt of agile electric Portable Utilitarian Vehicle (PUV)

• Design & fabricate exterior covers for various configurations at low-cost and high speed.

Showpiece at CommunicAsia 2017

Start-up

Adoption of 3D printing allows prototyping & design configuration studies to be carried out at lower cost & low-vol. runs cf. injection molding.

Design for multi-material, multi-colour parts for life-like visual effect SME

• Design for AM with multi-material, multi-colour attributes & achieving life-like visual effect. ☞ Potential use in automating fabrication of prosthetics and human organ models for surgical planning.

For illustration Pictures obtained from various sources

Artificial eye: Conven- tional manual process

AM-fabricated eye - Features close to actual eye, with improved accuracy

Geometric Modeling

Simulation Material Design for smooth deflection

Kajima et al., 2016

Homogenous structure – odd deflection

Optimised composite structure

• Design and model architecture and

layout of carbon fiber reinforced

composite for UAV components

• Fabrication of large composite UAV

components

3D printing

(FDM) with

continuous

fiber

reinforced

polymer

(Markforge)

UAV Composites

Multimaterial Design & AM

“AM-aware”

Computer-Aided

Design

Input image

50 100 150 200 250

50

100

150

200

250

Process Design

Find: process variables

Satisfy: process constraints

Minimize: time, cost

Materials Design

Find: volume fractions, grain

size, shape

Satisfy: compatibility

constraints

Maximize: energy absorption,

mech properties

Part/Product Design

Find: dimension values

Satisfy: stress, strain

Maximize: energy

absorption

Process ↔ Structure ↔ Property ↔ Performance

Design Problem

Formulation

Multi-Objective

Optimization

Methods

Encoding of microstructure using

Surfacelet coefficients

“Zoom-in” and “Zoom-out” operations

enabled by Surfacelet

CAD methods enabled by geometric model

Integrated Product – Material – Process – Design Method

New Frontiers in AM - 4D Printing - Printed Power - Soft Robotics

Common practice:

Discrete motors, pumps, voice

coils, gears, bearings,

sensors, etc

Desired practice:

Smart materials that actuate,

transform and self-assemble based on

desired design, are light-weight and simple

to integrate

Automotive:

Responsive car

aero foil

Aerospace:

Morphing wings

concept (NASA)

Medical:

Self deploying

medical devices

Complex mechanism,

needs assembly, many

moving parts…

4D printing

3D Printing Active Materials 4D Printing +

Shape memory polymer (SMP)

Shape change with “time”

Ge Qi, et al

4D

Printing

3D Printing

Approaches

Material

Development

Modeling

and

Simulation

4D Printing DMD Toolchain & Workflow

Multimaterial Polyjet printing

Formulate new materials

Digital composites

Material A

Material B

Composites (@ voxel control)

A B

Multimaterial Projection Micro Stereolithography

Thermomechanical constitutive modeling

Multiphysics Topology Optimization

4D printing enables creation of light-weight, inexpensive and simple to integrate actuating and

transforming components which may find applications in

Potential Applications of 4D Printing

Biomedical device

Self-folding/unfolding robots

Soft Robots

Potential

applications of

4D printing

Morphing wings Deployable structure

Foldable Furniture

*Industrial projects

Advantages for 3D printed LIBs

3D electrodes design: High areal-loading density (high energy density) Short ion-diffusion distance (high power density)

3D printed LIBs: Top-down technology Controlled pattern, shape. Fast prototyping. Compatible with whole printing electronics. Print solid electrolyte to solve safety issue. Print package with special functions, such as self-healing.

http://www.3ders.org/articles/20141024-graphene-3d-lab-unveils-first-3d-printed-graphene-battery.html

3D Printed Power – LIBs

Advantages for 3D printed LIBs

3D electrodes design: High areal-loading density (high energy density) Short ion-diffusion distance (high power density)

3D printed LIBs: Top-down technology Controlled pattern, shape. Fast prototyping. Compatible with whole printing electronics. Print solid electrolyte to solve safety issue. Print package with special functions, such as self-healing.

http://www.3ders.org/articles/20141024-graphene-3d-lab-unveils-first-3d-printed-graphene-battery.html

Wang Y. et al. Advanced Energy Materials

3D Printed Power – LIBs

•Printing process to create 3D battery as power source for micro-electronics

•Direct ink writing (DIW) method

•Design freedom: high flexibility in size & shape of the battery; printing on various substrates, and even curved surface

Robot

Direct Write 3D Printer

Accomplishment: 3D Printed micro-LIBs

Dispenser

Robot

Various substrates

Glass

PET

Printed single layer

Printed Micro-LIBs: Multi layers

6-layer, printed PDMS package

Industry project: Freeform 3D printed batteries for micro-electronics in drones

• Commercial space launch vehicles employing a proprietary

hybrid rocket technology

• Multi-material hybrid fuel grains that are designed and 3D

printed

3D Printing of Hybrid Rocket Fuel

Test rocket successfully launched in Queensland, Australia in Jul 2016. - 3D-printed fuel technology - 3.6m rocket | 5km

Multimaterial printer

Hybrid fuel grain

Lim, et al

Example

Thrust schedule created by designing interior propellant geometry

Stretchable conductive circuit

Ge et al. Scientific Report, 2016.

unpublished

Soft Robotics – Functional Materials

Smart Materials / 4D Printing • Large deformations in response

to heat, moisture, electricity, etc. • Can generate stresses required

for actuation.

3D printable hyperelastic soft materials • Deformations of more than 10 times its

initial length • Can accommodate large strains needed

for actuation (e.g. pneumatic soft actuators)

Conductive stretchable materials • Highly stretchable & 3D printable

electric conductors. • Can provide the structure for flexible

circuits and sensors

Scientists produce

world’s most

stretchable 3D

printable elastomer

Applications in Manufacturing

Soft robotic grippers: Adaptive grippers that conform to irregular & delicate objects

2. Fully 3D printed pneumatic-

based grippers

1. Cable-driven high payload grippers

New approaches to design and fabricate actuation, locomotion and sensing mechanisms in multimaterial soft systems & products

• Internship Opportunities • Capstone Projects • Sponsor PhD students through IPP • Collaborative Research Projects

– Option for company to own the FIP, depending on the funding structure

• Research Programs, Joint Labs / Corp Labs

SUTD – Partnering Industry

• National Additive Manufacturing Innovation Cluster (NAMIC) is a National Initiative to accelerate translation of upstream 3D printing research into commercial applications for industry adoption.

NAMIC Introduction

NAMIC Hub NAMIC Hub

3D printing initiative for Medical Technologies

Singapore Centre for 3D Printing (SC3DP)

Digital Manufacturing & Design Centre

NAMIC Hub

Industry Development 1. Raise awareness, training and certification of professionals 2. Promote adoption of AM across various industries, e.g. industrial collaboration projects

Technology Development 4. Translate IPs of high commercial potential and industry relevance 5. Develop new industrial standards for AM (local and international)

NAMIC Funding & Project Evaluation Process

NAMIC HUB • Problem Statement

Definition • Project Scoping,

Structuring, Management and Execution

• Industry Capability Development

• Competency Creation • Commercialization

Planning and Support

Industry Partners

Ecosystem Partners

Research Performers

Project Evaluation and Selection

• Industrial Implementation

• Commercial Product

• New Business • Start-ups &

Spinoffs

Project Execution

Commercialisation

NAMIC provides matching funding up to $250K for R&D projects in AM

* Shows examples

Our Partners*

Acknowledgements

• NRF, MOE, NAMIC, EDB, SPRING

Our Team*

Thank You