Additive Manufacturing and Stress Analysis of Naturally and Artificially Optimized Celullar Structures

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Jose, Sachin
Cellular Structures
thesis / dissertation description
The main objective of our research is to manufacture topology optimized cellular structures using 3D printing and polymer infusion and obtain their structural response. First, we have obtained topology optimized cellular structure of beam using an in-house topology optimization tool. The Solid Isotropic material with Penalization (SIMP) method of optimization is used for finding the optimal topology. Since we require a continuous structure where we can take advantage of additive manufacturing, a no-penalty approach was chosen. For 3D printing, first the optimized condition for manufacturing was determined. Important parameters on which manufacturing depend are Number of Shells, Infill percentage and Layer thickness. Then we manufacture the optimized structures using Fused Deposition Modeling. Next we fill the voids of the structures using polyurethane foam. The performance of the structures are first assessed by performing static tensile/compression test followed by bending tests and also by using Finite element based stress analysis in ABAQUS