Generativ design genom additiv tillverkning

Abstract

In this thesis study, which is examined at Chalmers University of Technology and perfomed in co-operation with Yovinn, it is evaluated how generative design and additive manufacturing function as tools to optimize a product’s strength and weight. In addition, it was also investigated how the workflow, costs and manufacturingprocesses differs compared to traditional design methods. The reference object for this study is supplied by Volvo Cars through the Industrial design consulting firm Yovinn and is called Detalj X in the report. During the work, a clear framework has been set up to highlight the pros and cons with generative design as a novel design process. Two concepts were also created through the generative design software, where one of the concepts was optimized to be manufactured in a plastic PA 12, and is called Detalj P, and the other in aluminum and is called Detalj Y. The result was two new part designs that had a significantly lower weight than Detalj X, but still had the same mechanical perfomance according to the framework and requirements. However, this resulted in a cost increase if manufacturing Detalj P and Detalj Y with additive manufacturing compared to the conventional manufacturing technology currently used for Detalj X. Furthermore, a load case study was also conducted with the generative design software Autodesk Fusion 360. The purpose of this load case study was to understand if the concepts that were generated would change depending on where the load cases were defined. The results obtained, clearly illustrates that generative design and additive manufacturing are efficient tools for optimizing complex parts as weight is reduced while mechanical perfomance can be retained. The generated parts were so complex that that additive manufacturing was the only option. Furthermore, the load case-studies showed that the results of the generated parts will not differ hugely depending on where they are defined if they are in the same direction and magnitude. This makes generative design a user friendly and efficient tool to create parts for manufacturing.