Optimal toolpath generation system and method for additively manufactured composite materials

Lewicki, James; Compel, William; Tortorelli, Daniel; Fernandez-Ayala, Felipe

Title: Optimal toolpath generation system and method for additively manufactured composite materials

Patent · Tue Aug 10 00:00:00 EDT 2021

OSTI ID:1840325

Lewicki, James; Compel, William; Tortorelli, Daniel; Fernandez-Ayala, Felipe

The present disclosure relates to a system for optimizing an additive manufacturing (AM) process. The system may use a printing component for using a material to form a component in a layer-by-layer process. An electronic controller may control movement of one of the printing component or a substrate on which the component is being formed, in a manner to optimize a toolpath for the printing component as each layer of the component is formed. Optimization operations are performed using an optimization subsystem which enables manufacturability constraints, as well as optimized toolpaths for each layer of the component, to be defined using contours of a level-set function. The level-set function may be used to define the optimized toolpaths within a fixed, predetermined grid, and the optimized toolpaths then used to generate suitable code for controlling movement of the printing component relative to the substrate to create the part or structure in a layer-by-layer process, using the optimized toolpaths.

View Patent

Cite

Export

Save

Research Organization:: Lawrence Livermore National Laboratory (LLNL), Livermore, CA (United States); Univ. of Illinois, Urbana-Champain, IL (United States)

Sponsoring Organization:: USDOE

DOE Contract Number:: AC52-07NA27344

Assignee:: Lawrence Livermore National Security, LLC (Livermore, CA); The Board of Trustees of the University of Illinois (Urbana, IL)

Patent Number(s):: 11,084,223

Application Number:: 16/105,459

OSTI ID:: 1840325

Resource Relation:: Patent File Date: 08/20/2018

Country of Publication:: United States

Language:: English

References (39)

Tool path generation for multi-axis freeform surface finishing with the LKH TSP solver Lin, Zhiwei; Fu, Jianzhong; Shen, Hongyao Computer-Aided Design, Vol. 69 https://doi.org/10.1016/j.cad.2015.07.002	journal	December 2015
Stiffness predictions for unidirectional short-fiber composites: Review and evaluation Tucker III, Charles L.; Liang, Erwin Composites Science and Technology, Vol. 59, Issue 5 https://doi.org/10.1016/S0266-3538(98)00120-1	journal	April 1999
3D-Printing of Meso-structurally Ordered Carbon Fiber/Polymer Composites with Unprecedented Orthotropic Physical Properties Lewicki, James P.; Rodriguez, Jennifer N.; Zhu, Cheng Scientific Reports, Vol. 7, Issue 1 https://doi.org/10.1038/srep43401	journal	March 2017
Design of variable stiffness composite panels for maximum fundamental frequency using lamination parameters Abdalla, Mostafa M.; Setoodeh, Shahriar; Gürdal, Zafer Composite Structures, Vol. 81, Issue 2 https://doi.org/10.1016/j.compstruct.2006.08.018	journal	November 2007
Apparatus and Method to Predetermine a Mechanical Property of a Three-dimensional Object Built by Additive Manufacturing Hayes, Michael W.; Strahm, Loren J.; Cuddy, Nathanial C. https://doi.org/https://image-ppubs.uspto.gov/dirsearch-public/print/downloadPdf/20170136703 US Patent Application 14/939336; 20170136703	patent-application	May 2017
Buckling Response of Laminates with Spatially Varying Fiber Orientations Olmedo, Reynaldo; Gurdal, Zafer 34th Structures, Structural Dynamics and Materials Conference https://doi.org/10.2514/6.1993-1567	conference	February 2013
Analysis of tow placed, parallel fiber, variable stiffness laminates Waldhart, C.; Gurdal, Z.; Ribbens, C. 37th Structure, Structural Dynamics and Materials Conference https://doi.org/10.2514/6.1996-1569	conference	February 2013
A survey of manufacturing oriented topology optimization methods Liu, Jikai; Ma, Yongsheng Advances in Engineering Software, Vol. 100 https://doi.org/10.1016/j.advengsoft.2016.07.017	journal	October 2016
Topological derivative-based topology optimization of structures subject to Drucker–Prager stress constraints Amstutz, S.; Novotny, A. A.; de Souza Neto, E. A. Computer Methods in Applied Mechanics and Engineering, Vol. 233-236 https://doi.org/10.1016/j.cma.2012.04.004	journal	August 2012
Generating Curvilinear Fiber Paths from Lamination Parameters Distribution Setoodeh, Shahriar; Blom, Adriana; Abdalla, Mostafa 47th AIAA/ASME/ASCE/AHS/ASC Structures, Structural Dynamics, and Materials Conference 14th AIAA/ASME/AHS Adaptive Structures Conference 7th https://doi.org/10.2514/6.2006-1875	conference	June 2012
Curvilinear fiber optimization tools for design thin walled beams Zamani, Z.; Haddadpour, H.; Ghazavi, M. R. Thin-Walled Structures, Vol. 49, Issue 3 https://doi.org/10.1016/j.tws.2010.08.002	journal	March 2011
An optimization approach for path planning of high-quality and uniform additive manufacturing Jin, Yuan; Du, Jianke; Ma, Zhiyong The International Journal of Advanced Manufacturing Technology, Vol. 92, Issue 1-4 https://doi.org/10.1007/s00170-017-0207-3	journal	March 2017
Design of variable-stiffness composite panels for maximum buckling load Setoodeh, Shahriar; Abdalla, Mostafa M.; IJsselmuiden, Samuel T. Composite Structures, Vol. 87, Issue 1 https://doi.org/10.1016/j.compstruct.2008.01.008	journal	January 2009
Isogeometric shape optimization of vibrating membranes Manh, Nguyen Dang; Evgrafov, Anton; Gersborg, Allan Roulund Computer Methods in Applied Mechanics and Engineering, Vol. 200, Issue 13-16 https://doi.org/10.1016/j.cma.2010.12.015	journal	March 2011
Fiber path definitions for elastically tailored conical shells Blom, Adriana W.; Tatting, Brian F.; Hol, Jan M. A. M. Composites Part B: Engineering, Vol. 40, Issue 1 https://doi.org/10.1016/j.compositesb.2008.03.011	journal	January 2009
Design sensitivity analysis: Overview and review Tortorelli, D. A.; Michaleris, P. Inverse Problems in Engineering, Vol. 1, Issue 1 https://doi.org/10.1080/174159794088027573	journal	October 1994
Implicit method and an algorithm for flexible functionally tailorable slicing for additive manufacturing Michopoulos, John; Iliopoulos, Athanasious; Steuben, John https://doi.org/https://image-ppubs.uspto.gov/dirsearch-public/print/downloadPdf/20180157243 US Patent Application 15/829088; 20180157243	patent-application	June 2018
Generating realistic laminate fiber angle distributions for optimal variable stiffness laminates van Campen, Julien M. J. F.; Kassapoglou, Christos; Gürdal, Zafer Composites Part B: Engineering, Vol. 43, Issue 2 https://doi.org/10.1016/j.compositesb.2011.10.014	journal	March 2012
Curvilinear fiber optimization tools for aeroelastic design of composite wings Haddadpour, H.; Zamani, Z. Journal of Fluids and Structures, Vol. 33 https://doi.org/10.1016/j.jfluidstructs.2012.05.008	journal	August 2012
A level set based method for fixing overhangs in 3D printing Cacace, Simone; Cristiani, Emiliano; Rocchi, Leonardo Applied Mathematical Modelling, Vol. 44 https://doi.org/10.1016/j.apm.2017.02.004	journal	April 2017
Topology optimization of 3D self-supporting structures for additive manufacturing Langelaar, Matthijs Additive Manufacturing, Vol. 12 https://doi.org/10.1016/j.addma.2016.06.010	journal	October 2016
Optimization of tow fiber paths for composite design Nagendra, S.; Kodiyalam, Srinivas; Davis, Jonathan 36th Structures, Structural Dynamics and Materials Conference https://doi.org/10.2514/6.1995-1275	conference	February 2013
Computational design of curvilinear bone scaffolds fabricated via direct ink writing Roberge, Jeffrey; Norato, Julián Computer-Aided Design, Vol. 95 https://doi.org/10.1016/j.cad.2017.09.003	journal	February 2018
Toolpath optimization for minimizing airtime during machining Castelino, Kenneth; D'Souza, Roshan; Wright, Paul K. Journal of Manufacturing Systems, Vol. 22, Issue 3 https://doi.org/10.1016/S0278-6125(03)90018-5	journal	January 2003
Deposition path planning-integrated structural topology optimization for 3D additive manufacturing subject to self-support constraint Liu, Jikai; To, Albert C. Computer-Aided Design, Vol. 91 https://doi.org/10.1016/j.cad.2017.05.003	journal	October 2017
Intelligent 3D Printing Through Optimization of #D Print Parameters Lin, Pierre Pascal Anatole; Willis, Karl; Wilhelm, Eric Jamesson https://doi.org/https://image-ppubs.uspto.gov/dirsearch-public/print/downloadPdf/20150331402 US Patent Application 14/711714; 20150331402	patent-application	November 2015
Optimum design of composite structures with curved fiber courses Parnas, Levend; Oral, Süha; Ceyhan, Ümit Composites Science and Technology, Vol. 63, Issue 7 https://doi.org/10.1016/S0266-3538(02)00312-3	journal	May 2003
Optimized Additive Manufacturing Process Zalewski, Bart F. https://doi.org/https://image-ppubs.uspto.gov/dirsearch-public/print/downloadPdf/20150360288 US Patent Application 14/739739; 20150360288	patent-application	December 2015
Topology Optimization for Additive Manufacturing: Considering Maximum Overhang Constraint Gaynor, Andrew T.; Meisel, Nicholas A.; Williams, Christopher B. 15th AIAA/ISSMO Multidisciplinary Analysis and Optimization Conference https://doi.org/10.2514/6.2014-2036	conference	June 2014
A novel fiber optimization method based on normal distribution function with continuously varying fiber path Kiyono, C. Y.; Silva, E. C. N.; Reddy, J. N. Composite Structures, Vol. 160 https://doi.org/10.1016/j.compstruct.2016.10.064	journal	January 2017
Optimization of course locations in fiber-placed panels for general fiber angle distributions Blom, Adriana W.; Abdalla, Mostafa M.; Gürdal, Zafer Composites Science and Technology, Vol. 70, Issue 4 https://doi.org/10.1016/j.compscitech.2009.12.003	journal	April 2010
Advanced lattice support structures for metal additive manufacturing Hussein, Ahmed; Hao, Liang; Yan, Chunze Journal of Materials Processing Technology, Vol. 213, Issue 7 https://doi.org/10.1016/j.jmatprotec.2013.01.020	journal	July 2013
Design of variable-stiffness composite layers using cellular automata Setoodeh, Shahriar; Gürdal, Zafer; Watson, Layne T. Computer Methods in Applied Mechanics and Engineering, Vol. 195, Issue 9-12 https://doi.org/10.1016/j.cma.2005.03.005	journal	February 2006
Buckling analysis and optimisation of variable angle tow composite plates Wu, Zhangming; Weaver, Paul M.; Raju, Gangadharan Thin-Walled Structures, Vol. 60 https://doi.org/10.1016/j.tws.2012.07.008	journal	November 2012
An additive manufacturing filter for topology optimization of print-ready designs Langelaar, Matthijs Structural and Multidisciplinary Optimization, Vol. 55, Issue 3 https://doi.org/10.1007/s00158-016-1522-2	journal	July 2016
Characterization of Effect of Support Structures in Laser Additive Manufacturing of Stainless Steel Järvinen, Jukka-Pekka; Matilainen, Ville; Li, Xiaoyun Physics Procedia, Vol. 56 https://doi.org/10.1016/j.phpro.2014.08.099	journal	January 2014
Structural Design Using Optimality Based Cellular Automata Abdalla, Mostafa; Gurdal, Zafer 43rd AIAA/ASME/ASCE/AHS/ASC Structures, Structural Dynamics, and Materials Conference https://doi.org/10.2514/6.2002-1676	conference	June 2012
Scaffold-free inkjet printing of three-dimensional zigzag cellular tubes Xu, Changxue; Chai, Wenxuan; Huang, Yong Biotechnology and Bioengineering, Vol. 109, Issue 12 https://doi.org/10.1002/bit.24591	journal	July 2012
New optimization method for steered fiber composites using the level set method Brampton, Christopher J.; Wu, K. Chauncey; Kim, H. Alicia Structural and Multidisciplinary Optimization, Vol. 52, Issue 3 https://doi.org/10.1007/s00158-015-1256-6	journal	May 2015

Similar Records

Additive manufacturing system and method having toolpath analysis

Patent · Tue Feb 23 00:00:00 EST 2021 · OSTI ID:1840325

King, Michael J.; Fellini, Ryan A.

Optimal toolpath design of additive manufactured composite cylindrical structures

Journal Article · Fri Jan 22 00:00:00 EST 2021 · Computer Methods in Applied Mechanics and Engineering · OSTI ID:1840325

Fernandez, Felipe; Lewicki, James P.; Tortorelli, Daniel A.

Reinforcement Learning for Generating Toolpaths in Additive Manufacturing

Conference · Wed Aug 01 00:00:00 EDT 2018 · OSTI ID:1840325

Patrick, Steven; Nycz, Andrzej; Noakes, Mark; +1 more

Title: Optimal toolpath generation system and method for additively manufactured composite materials

Citation Formats

References (39)

Similar Records

Related Subjects