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2.1 Stock Extra-Material Optimisation Workflow


2.1 Stock Extra-Material Optimisation Workflow

This workflow aims at minimizing the additional extra material that needs to be removed (by e.g. CNC machines) to create an optimal surface after the AM printing process.

To this end, we would like to design an appropriate stock part, keeping into account the distortions induced by thermal effects during the AM printing process.

Assuming that

  • the stock part is generated starting from the nominal geometry, by adding a constant offset to each of its external surfaces;
  • the presence of internal cavities might reduce the distortion of the stock part during the printing process;

the design parameters on which we can operate are then the amount of offset and the void generation parameters. In practice we perform the optimization by predicting by numerical simulation the distortions of a number of possible stock part designs, and then extrapolating from these results the optimal design, through what can be called in mathematical terms “sparse-grid based surrogate model optimization”.

The software functionalities for such mathematical approach are provided by the SG++ software (link here).


J. Valentin and D. Pflüger: Hierarchical Gradient-Based Optimization with B-Splines on Sparse Grids. In J. Garcke, D. Pflüger (ed.), Sparse Grids and Applications – Stuttgart 2014, Volume 109 of Lecture Notes in Computational Science and Engineering, pp. 315–336. Springer, March 2016.
CaxMan D2.5 Analysis Tool for AM Linear Setting
CaxMan D2.6 Analysis Based Optimisation Tools - PLACEHODER



Additional Information

Originator: Lorenzo Tamellini (CNR/IMATI)
Technology Readiness Level: 3
Environment: 0 Market Place