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Proceedings Paper

Incorporating manufacturability constraints into the design process of heterogeneous objects
Author(s): Yuna Hu; Vincent Y. Blouin; Georges M. Fadel
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Paper Abstract

Rapid prototyping (RP) technology, such as Laser Engineering Net Shaping (LENSTM), can be used to fabricate heterogeneous objects with gradient variations in material composition. These objects are generally characterized by enhanced functional performance. Past research on the design of such objects has focused on representation, modeling, and functional performance. However, the inherent constraints in RP processes, such as system capability and processing time, lead to heterogeneous objects that may not meet the designer's original intent. To overcome this situation, the research presented in this paper focuses on the identification and implementation of manufacturing constraints into the design process. A node-based finite element modeling technique is used for the representation and analysis and the multicriteria design problem corresponds to finding the nodal material compositions that minimize structural weight and maximize thermal performance. The optimizer used in this research is a real-valued Evolutionary Strategies (ES), which is well suited for this type of multi-modal problem. Two limitations of the LENS manufacturing process, which have an impact on the design process, are identified and implemented. One of them is related to the manufacturing time, which is considered as an additional criterion to be minimized in the design problem for a preselected tool path. A brake disc rotor made of two materials, aluminum for lightweight and steel for superior thermal characteristics, is used to illustrate the tradeoff between manufacturability and functionality.

Paper Details

Date Published: 11 November 2004
PDF: 12 pages
Proc. SPIE 5605, Intelligent Systems in Design and Manufacturing V, (11 November 2004); doi: 10.1117/12.571507
Show Author Affiliations
Yuna Hu, Clemson Univ. (United States)
Vincent Y. Blouin, Clemson Univ. (United States)
Georges M. Fadel, Clemson Univ. (United States)


Published in SPIE Proceedings Vol. 5605:
Intelligent Systems in Design and Manufacturing V
Bhaskaran Gopalakrishnan, Editor(s)

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