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Generative design is a software tool that enables engineers and designers to approach design problems in more innovative and efficient ways. Generative design algorithms explore all possible design solutions by defining goals and constraints, offering engineers numerous options to explore<\/strong>.<\/p>\n Although still in its infancy, generative design has shown remarkable potential for industrial applications, particularly when coupled with 3D printing. Together, generative design and 3D printing can achieve more design flexibility, while creating lighter and stronger parts.<\/p>\n Today, we\u2019ll be looking at the benefits and current challenges of using generative design, particularly when coupled with 3D printing. We\u2019ll also explore some of the most popular generative design software used with 3D printing and take a look at the companies leveraging generative design technology to drive innovation.<\/p>\n Generative design is a fairly new technology. As with any new technology, there remains a lack of industry consensus around its definition. In spite of this, there seem to be two main ways of looking at generative design: either as a broad term encompassing topology optimisation or as an entirely distinct technology.<\/p>\n A common view of generative design describes it as a technology which makes use of powerful computation to assist in the design process.<\/p>\n Here\u2019s a step-by-step look at how generative design works:<\/p>\n The designer specifies and sets the parameters for the part design, based on parameters such as weight, material, size, cost, strength, and manufacturing methods.<\/p>\n The generative design software uses algorithms to explore and generate thousands of design options. At this stage, the software can also use AI-powered algorithms to analyse each design and establish the most efficient designs.<\/p>\n The designer can then study these designs and select the outcomes which best meet the design goal.<\/p>\n To determine the geometry of the design, generative design algorithms may use a range of different approaches, such as topology optimisation, biomimicry and morphogenesis.<\/p>\n The main difference between these approaches is that topology optimisation algorithms typically start with a pre-existing design and remove the material from it to reduce part\u2019s weight.<\/p>\n Biomimicry and morphogenesis, in contrast, mimic nature\u2019s evolutionary approach to design, like the growth of roots and branches in trees, or the evolution of bone structures, using this to generate design options.<\/p>\n When used with 3D printing, the benefits can be further expanded to include decreased manufacturing costs and increased productivity. We\u2019ve identified 3 core advantages: 2. Lightweighting<\/b><\/p>\n Generative design tools give engineers the resources to create lightweight parts using the minimum amount of material necessary, whilst adhering to the engineering requirements.<\/p>\n Generative design can provide solutions to consolidate subassemblies into a single part. Consolidating parts simplifies the assembly process, maintenance and can reduce overall manufacturing costs.<\/p>\n Generative design software helps to conceptualise parts with complex, organic shapes. 3D printing, on the other hand, is perhaps the ideal technology to bring these shapes to life, since it is not only capable of creating complex geometries but also does it cost-effectively. With traditional manufacturing, producing these shaped might often be impractical, if not impossible, either due to high costs or the limitations of the technology.<\/p>\n However, it would be misleading to state that generative design is limited to only additive manufacturing, although in many cases the technology will be the most optimal production method. With some generative design software packages, you can specify manufacturing methods like CNC machining, casting or injection moulding, in addition to AM.<\/p>\n Currently, generative design is in an early stage of development, which means early users may come across certain challenges.<\/p>\n For example, accurately defining a design problem in computable terms, which generative design software has to solve, will involve a steep learning curve. Engineers inexperienced with expressing the design problem as a set of parameters may end up with loosely defined structural constraints or loads, which will ultimately result in a failed design.<\/p>\n Another point to consider with generative design is that efficient designs are not always can be efficiently manufactured. For example, in a Renishaw case study, engineers topologically optimised a suspension bell-crank. They didn\u2019t, however, take into account the manufacturability of the optimised part. This resulted in a design that required a lot of supports to be printed, whereas a good practice is to design parts with as few supports needed as possible.<\/p>\n Furthermore, designs created with the help of generative design tools can create geometries that are challenging even for 3D printing. Overhanging features and thin walls are just a couple of examples of this. However, new generative design tools provide options allowing the user to specify additional manufacturing data like overhang angles and minimum wall thickness. Lastly, generative design approaches can be computationally intensive and require powerful computing capabilities of the hardware. However, more and more companies offer generative design software that leverages cloud computing, eliminating the need to invest in expensive hardware.<\/p>\n While the market for generative design software is new, there are already a number of software packages available for both additive and subtractive manufacturing. In this section, we\u2019ll take a look at some of the most promising offerings in generative design for 3D printing.<\/p>\n Autodesk has been at the forefront of generative design development. In April, the company launched its Autodesk Generative Design platform, incorporated into its cloud-based Fusion 360 Ultimate product development software.<\/p>\n The platform allows engineers to define design parameters like material, size, weight, strength, manufacturing methods, and cost constraints. Notably, the software uses AI-based algorithms, which help to filter valid designs among an array of design options. The software also takes manufacturability into account, allowing designers to select up to ten different additive manufacturing materials to study the design.<\/p>\n Frustum, a young company founded in 2014, is looking to become a significant player in the generative design field. The company\u2019s offering is its GENERATE software \u2013 an intuitive program for creating topology-optimized components for additive manufacturing, milling and casting. GENERATE is a cloud-based platform, available in three tiers: Free, Professional, and Enterprise.<\/p>\n In GENERATE, the user assigns particular load and constraint values to the faces of a part. The program, powered by Frustum\u2019s generative design engine TrueSOLID\u24c7, then generates a finite element analysis (FEA) map of stress concentrations. With this map, the users can make modifications to the part\u2019s geometry, particularly to reduce the amount of unnecessary material in its structure. The model can be saved in STL format and is ready to be 3D printed.<\/p>\n Last year Frustum announced a partnership with Siemens, and currently, the technology is commercially licensed to Siemens PLM software and integrated into Siemens NX and Siemens SolidEdge.<\/p>\nWhat is generative design?<\/h2>\n
1. Set parameters<\/strong><\/h3>\n
2. Generate designs<\/strong><\/h3>\n
3. Select the best options<\/strong><\/h3>\n
The benefits of generative design<\/h2>\n
\n<\/b><\/p>\n1. Innovative design options<\/b><\/h3>\n
Generative design software can produce geometries that go beyond what humans can conceive, thereby enhancing human capabilities in product design.<\/h3>\n
3. Part consolidation<\/b><\/h3>\n
Why is generative design a perfect fit for 3D printing?<\/h2>\n
The challenges of generative design<\/h2>\n
#1: Learning curve<\/b><\/h3>\n
#2: Gap between design and manufacture<\/b><\/h3>\n
#3: Challenging geometries<\/b><\/h3>\n
\n<\/b><\/p>\n#4: Resources needed<\/b><\/h3>\n
Generative design software solutions for 3D printing<\/h2>\n
Autodesk Generative Design<\/b><\/h3>\n
How it works<\/b><\/h4>\n
Frustum GENERATE<\/b><\/h3>\n
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<\/p>\nHow it works<\/b><\/h4>\n
Desktop Metal\u2019s Live Parts\u2122<\/b><\/h3>\n
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