Topology and Morphology Optimization of 3D Printed Continuous Fiber Composites
Abstract
The goal of proposed research is to create and experimentally validate an innovativeframework for design optimization of continuous fiber morphology (fiber infill pattern) andgeometric topology (shape and lay-out) in order to achieve unprecedented mechanical performancein multi-layer 3D printed composite structures. The proposed framework will allow a paradigmshift from optimizing conventional unidirectional fibers to manufacturable continuous fiber 3Dprinted (CF3D) composites. While superior mechanical properties, cost-effectiveness, and highlytailored structural performance of CF3D make them the future of composite 3D printing, thetechnology is years ahead of the science: (1) On the optimization front, the topology andmorphology optimization of multi-layer CF3D has not been investigated; (2) On the fabricationfront, manufacturing constraints must be implemented in the design optimization process to ensuremanufacturability; and (3) On the mechanics front, failure of CF3D composites is not yetunderstood. To address these challenges, the PI proposes to employ topology optimization toobtain material distribution in each layer to maximize the stiffness and satisfy the weight, failure,and manufacturing constraints. A novel streamline-based theory is established to identify the infillpattern based on the traction field to further increase the stiffness. The streamlines are projectedonto the updated topology in each optimization iteration. The proposed streamline approachprovides full control of the printed filament length, which allows the implementation ofmanufacturing constraints in the design process to ensure fabrication feasibility. A computationaland experimental plan is proposed to characterize mechanical properties and elucidate failuremechanics for the CF3D parts.
Document Details
- Document Type
- DoD Grant Award
- Publication Date
- Jun 17, 2020
- Source ID
- N000142012683
Entities
People
- Ali A Tamijani
Organizations
- Embry–Riddle Aeronautical University
- Office of Naval Research
- United States Navy