Advanced Techniques in Porous Structure Design for Additive Manufacturing

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.

• Preface ixChapter 1 Introduction to Porous Structures and Additive Manufacturing 11.1 Introduction 11.2 Why Designing Porous Structures 61.3 Types of Cells 81.4 Challenges in the Design and Fabrication of Porous Structures 10References 12Chapter 2 Fundamentals of Additive Manufacturing 152.1 Introduction 152.2 Metallic Materials 162.3 Metallic Additive Manufacturing 202.4 Plastics 242.5 Plastic 3D Printing 262.6 Ceramics 282.7 Ceramic 3D Printing 292.8 The Production Cycle of 3D Printing 312.9 Challenges Facing Additive Manufacturing 342.10 Emerging Techniques in Additive Manufacturing 38References 41Chapter 3 Mathematical Modeling for the Calculation of Porous Structure Properties: Techniques and Applications 433.1 Introduction 433.2 Overview of Computational Assessments of Physical Properties of Materials 443.3 Mechanical Properties of Microstructure 473.4 Effective Elasticity Tensor for Porous Structures using FEM Formulation 57References 63Chapter 4 Advanced Techniques in Porous Structure Design 654.1 Introduction 654.2 Parametric Optimization 694.3 Non-Parametric Optimization 724.4 Multiphysics Topology Optimization Fundamentals 764.5 Topology Optimization Methodologies 814.6 Shape Optimization 864.7 Porous Structural Design 91References 97Chapter 5 Practical Examples and Case Studies 1035.1 Introduction 1035.2 Porous Heat Sink Designs with Non-Parametric Optimization 1035.3 Application of Robotics 128References 165Chapter 6 Advanced Software Utilization for Designing and Analyzing Porous Structures 1736.1 Introduction 1736.2 Commercial Software 1746.3 Coding-Based Commercial Software Design of Porous Structures 176References 192Chapter 7 Emerging Trends and Directions in Advanced Porous Structures 1957.1 Introduction 1957.2 Advanced Manufacturing 1967.3 Applications of Advanced Porous Structures 1977.4 Challenges and Future Directions 201References 202Index 207