Bionic Bracket for additive manufacturing
In aerospace, every kilogram of weight carried into space leads to high costs. Therefore, lightweight design is worthwhile even for smallest components. Modern launchers such as the Ariane 6 consist of multipLe parts. This arouses interest in engineering processes by means of which geometrically complex components for additive manufacturing processes are developed automatically,
Unlike conventional serial development processes with
sketch based construction and manual FE-iterations, Generative Engineering allows an automated generation of lightweight designs with real time adaption to changing boundary conditions in one software environment.
We created the technical DNA of the bracket structure rather than the component itself. Based on the technical specifications, the process generates and derives optimal load paths for the bionic bracket structure and dimensions them into a lightweight design structure. After a one-time setup of the development process, which we call the technical DNA, one loop of design interpretation and dimensioning takes approx. 10 min.
3D printed Airbus A 320 Auxiliary Stabilizing Point
The auxiliary stabilizing point is installed between two frames of the A320S lower shell at the rear side of the airplane. it is used in final assembly and during maintenance in order to keep the aircraft level. Therefore, it carries part of the airplanes weight.
Unlike conventional serial development processes with sketch based construction and manual FE-iterations, Generative Engineering allows an automated generation of lightweight designs with real time adaption to changing boundary conditions in one software environment. We created the technical DNA of the stabilizing point inlay rather than the component itself.
Within the DNA, the topology optimization visualizes load paths, which are adapted by parametric cross section optimization considering loads and manufacturing constraints. The automated smoothening of the structure and integration of attachment points is the last step of the automated process, leading to the final part for 3D printing
We are convinced that the way we develop technical products today will change fundamentally,
Engineers will no longer design and compute parts by hand in the future – they will develop solutions for automated design in close collaboration with computer and intelligent algorithms.
With more than 10 years of experience in researching bionic Lightweight constructions and the growth processes of nature, we have learned that natures complex structures are not directly designed, Only during growth it becomes clear how an organism ideally adapts to its individual boundary conditions of its environment. The variability in growth is based on a clearly defined set of rules. Nature has evolved an amazing solution to implement these rules into organisms. Nature developed the DNA.
Manufacturing techniques are getting better and better. 3D printing pushes the limits of what is possible even further. For the first time, we can produce structures whose complexity hardly influences production costs. In component development, however, this complexity leads to immensely increasing costs and development times. We are convinced that we must stop designing components this way. We need to start producing components automatically based on defined rules and regulations.
We need technical DNA.
Generative Engineering enables disruptive product innovations. Since all influencing factors such as design guidelines, costs or production restrictions directly influence the design, the agile process enables several automated iterations in the shortest possible time and leads to first-time-right designs. With our systematic innovation approach, we analyze your development processes and tools and identify the 3D printing potential of your components. A tailor-made roadmap guides your company on the way to Generative Engineering.
Do you want Generative Engineering to be applied to your company’s products? We develop the technicat DNA of your components with our Software ELISE. Our use cases provide a deep insight into DNA generation and deliver facts about the potential of Generative Engineering. Among others, state-of-the-art FEA-simulations, topology optimization, parametric optimization with DoE and evolutionary algorithms are features we implement into the DNA. Our use cases are also a good opportunity for training at your team’s workplace.
All is Grasshopper & Weavebird. RHINO Software Design.
Surface to skeleton rhino + grasshopper + weavebird +starling (David Stasiuk)