Advanced techniques in porous structure design for additive manufacturing / Musaddiq Al Ali.

Includes index.

Table of Contents
Preface ix

Chapter 1 Introduction to Porous Structures and Additive Manufacturing 1

1.1 Introduction 1

1.2 Why Designing Porous Structures 6

1.3 Types of Cells 8

1.4 Challenges in the Design and Fabrication of Porous Structures 10

References 12

Chapter 2 Fundamentals of Additive Manufacturing 15

2.1 Introduction 15

2.2 Metallic Materials 16

2.3 Metallic Additive Manufacturing 20

2.4 Plastics 24

2.5 Plastic 3D Printing 26

2.6 Ceramics 28

2.7 Ceramic 3D Printing 29

2.8 The Production Cycle of 3D Printing 31

2.9 Challenges Facing Additive Manufacturing 34

2.10 Emerging Techniques in Additive Manufacturing 38

References 41

Chapter 3 Mathematical Modeling for the Calculation of Porous Structure Properties: Techniques and Applications 43

3.1 Introduction 43

3.2 Overview of Computational Assessments of Physical Properties of Materials 44

3.3 Mechanical Properties of Microstructure 47

3.4 Effective Elasticity Tensor for Porous Structures using FEM Formulation 57

References 63

Chapter 4 Advanced Techniques in Porous Structure Design 65

4.1 Introduction 65

4.2 Parametric Optimization 69

4.3 Non-Parametric Optimization 72

4.4 Multiphysics Topology Optimization Fundamentals 76

4.5 Topology Optimization Methodologies 81

4.6 Shape Optimization 86

4.7 Porous Structural Design 91

References 97

Chapter 5 Practical Examples and Case Studies 103

5.1 Introduction 103

5.2 Porous Heat Sink Designs with Non-Parametric Optimization 103

5.3 Application of Robotics 128

References 165

Chapter 6 Advanced Software Utilization for Designing and Analyzing Porous Structures 173

6.1 Introduction 173

6.2 Commercial Software 174

6.3 Coding-Based Commercial Software Design of Porous Structures 176

References 192

Chapter 7 Emerging Trends and Directions in Advanced Porous Structures 195

7.1 Introduction 195

7.2 Advanced Manufacturing 196

7.3 Applications of Advanced Porous Structures 197

7.4 Challenges and Future Directions 201

References 202

Index 207

"Porous structure design is used in engineering to create lightweight materials with exceptional characteristics like high mechanical strength-to-weight ratios. These structures feature interconnected voids or pores, which reduce overall weight without compromising strength, making them ideal for applications where weight and energy consumption is a concern, such as the aerospace and automotive industries. Additive manufacturing has emerged as the go-to method for producing such intricate structures because it allows for precise control over the internal architecture, enabling the creation of complex geometries that are challenging or impossible to achieve with traditional manufacturing methods. However, transitioning from design to 3D printing poses its challenges, and ensuring the fidelity of the final printed product requires careful consideration of factors like material properties and printing parameters."-- Provided by publisher.

About the Author
Musaddiq Al Ali, PhD, is a research scientist at the Toyota Technological Institute, where his work on additive manufacturing methods for the creation of multifunctional, ultra-lightweight structures for smart vehicles is sponsored by the Toyota Corp. His career has included teaching undergraduate and postgraduate courses in mechanics, heat transfer, fluid dynamics, numerical methods, manufacturing processes, control systems, dynamics, computer-aided design, and mathematical programming.

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