CDFAM Berlin, 2024
Archive of recordings of presentations from CDFAM Berlin, May 7-8, 2024
Keynote Presentation
Presenter:
Dr. Andreas Vlahinos
Organization:
Advanced Engineering Solutions
Simulation-Driven Design of Lattice Structures
The world of additive manufacturing is constantly evolving, and we are fortunate to witness its growth with new machines, faster processes, and an abundance of new materials. Design practitioners are now enabled to unleash the full potential of AM using Generative Design and Lattice structures.
Lattice structures are topologically ordered, three-dimensional, open-celled structures used by nature. Lattice structures are observed in insects, birds, bones, and plants. Lattice structures are very effective for lightweight structural panels, energy absorption devices, thermal insulation, high-performance heat exchangers, ballistic protection, and porous implants.
Simulating lattice structures is not trivial. There are many challenges in the simulation of both the beam and surface lattices. The complexity of beam lattices makes it necessary to use multiple tetrahedron finite elements to describe a single-unit lattice cell. This creates a significant challenge in simulating components with large amounts of beam lattice structures. Minimal surfaces like Gyroids, Schwarz, Lidinoid, Diamond, SplitP, and Neovius have exceptional strength, heat transfer, and manufacturability properties. However, the simulation process is challenging because these minimal surface geometries are not typical B-Rep geometry. Instead, they are generated using implicit or voxel-based modelers. This presentation will demonstrate methods to overcome the beam and surface Lattice Structures’ simulation challenges.
In modern CAD tools, it is easy to generate Lattice Structures. Typically, in the past, the designer enters the cell type (Gyroid, Diamond, Stochastic, Star beam, etc.), the cell dimension (dx, dy, dz or number of unit cells), and the component size (beam diameter, gyroid thickness, etc.). The generated Lattice geometry can be simulated, and the performance requirements are evaluated.
This presentation aims to showcase the process of simulation-driven lattices that are utilized for designing and optimizing structures based on specific performance requirements. To begin with, a Generative Design is performed using homogenized material properties. Afterward, a simulation is executed on the Generative Design geometry, and the stress field is captured. Finally, the geometry is infilled with lattices, which come with variable cell and component sizes driven by the stress field. For instance, at high-stress regions, more stochastic cells are generated, or the gyroids are thicker.
These techniques offer a cost-effective and efficient way to explore a wide range of design possibilities and ensure that lattice structures meet desired criteria during the design stage.
Scaling Production through automation
Presenter:
Jesus Marini Parissi
Organization:
MoonrabbitX
Computational Processes for Adaptive Biomechanics
Moon Rabbit Adaptive Lab, in collaboration with ETH Zurich, has pioneered an innovative approach by merging advanced computational strategies with adaptable biomechanics. A key highlight of our work is the development of a 3D-printed robotic hand. This project, inspired by the human hand’s ergonomic and mechanical aspects, utilizes Inkbit’s multi-material 3D printing technology. Our team crafted hybrid structures blending soft and rigid components, employing a Grasshopper workflow for optimization. The result is an intricate balance of organic design and practical manufacturing, marking a leap forward in adaptable robotic technology. This initiative reflects our commitment to converting complex algorithms into practical, versatile solutions, cementing our path to becoming a frontrunner in computational design research.
Presenter:
Rhushik Matroja
Organization:
Cognitive Design Systems
Manufacturing Driven Design by Cognitive Design
Cognitive Design is a new generation software bridging CAD and Factory floor through manufacturing-driven design. It accelerates the design cycle of engineers through automation and makes sure all designs are manufacturable.
Presenter:
Florian Reichle
+ Gunnar Schulze
Organization:
trinckle
Find the Sweetspots in Industrial Design Automation
‘Find the Sweetspots in Industrial Design Automation’ encapsulates trinckle 3D’s innovative approach in leveraging computational design for both high- and low-volume production scenarios. Our cloud platform, paramate, with its native CAD Kernel is a script-based tool specifically developed for efficient, high-performance design automation, optimized for algorithm-driven design. This presentation will illuminate how automated design processes are instrumental in real-world applications, particularly in streamlining and scaling complex design workflows for a variety of industrial sectors.
Florian will showcase that especially in the industrial context there is a strong demand for repetitive design processes, advanced product customization or combinations of both. Paramate’s architecture uniquely combines algorithm-driven CAD with intuitive, interactive configuration interfaces, demonstrating trinckle’s commitment to innovative design automation solutions.
Real-world examples from industry giants like Volkswagen, Airbus, Deutsche Bahn, and Ford will demonstrate the tangible benefits of computational design in industrial contexts, such as significant reductions in design time and costs, and the enhancement of production efficiency.
Presenter:
René Medel
Organization:
framas
Generative DfAM in Footwear Industry
The traditional way of making shoes is evolving together with technology. The fabrication is turning more into digital processes like Additive Manufacturing and Automation. However, the ideation and design stages are also powered by Extended Reality (XR) and the adoption of Artificial Intelligence.
In this presentation will be covered the importance and influence of algorithmic design in applied cases in footwear, not just for prototyping or visualization, but also for development and industrial production, like foaming and injection molding.
Presenter:
Ruiqi Chen, Software Engineer, & Andrew Sink, Senior Application Engineer
Organization:
Carbon
The Road to One Million Custom Parts Per Month: Automated Production Pipelines for Customized Products at Scale
This presentation delves into the use of computational design and additive manufacturing in producing customized, high-performance applications at scale. We’re not talking hundreds or even thousands–Carbon is on a mission to produce one million custom parts per month. Highlighting a collaboration between software developers and engineers at Carbon, this presentation showcases the unique scientific and technical challenges with a mission of this scale and complexity, and the solutions developed along the way.
As a leader in bringing additive manufactured, high-performance products to market, we’ll focus on the methodology behind developing an automated workflow for custom parts, including computational design techniques, dual cure material science, and the adoption of additive manufacturing processes.
The discussion will cover critical aspects such as design optimization, performance simulation, and the challenges of production scalability. Attendees will gain insights into the precise application of computational tools in enhancing product customization and performance, reflecting on the potential for future advancements in manufacturing technology.
Software and applications
Presenter:
Moritz Valentino Huber
Organization:
Hyperganic
Democratizing Advanced Engineering Solutions from Industrial to Medical Applications
Moritz Valentino Huber is the Director of Engineering at Hyperganic, a company at the vanguard of the advanced manufacturing sector, especially in 3D printing, with operations in Munich and Singapore. With an extensive professional background spanning over eight years in additive manufacturing, Moritz Valentino’s contributions began at the Fraunhofer Institute IGCV, focusing on multi-material Laser Beam Powder Bed Fusion (LBPF) printing. His career highlights include pioneering work at ArianeGroup on the Space4.0 initiative, integrating Metal LBPF printers with Ethernet for enhanced manufacturing digitalization, and developing predictive maintenance models for Metal LBPF machines using machine learning. At Hyperganic, he leads engineering efforts to address key challenges in sustainability and efficiency in the fields of thermal management, lightweighting and next gen consumer goods through the combination of innovative software solutions and addtive manufacturing.
Presenter:
Thomas Rees
Organization:
ToffeeX
Industrializing Physics-Driven Generative Design
Physics-driven design tools such as topology optimization, while transformative at the conceptual level in engineering, have yet to significantly impact production components due to limited adoption in industry workflows. Through a series of case studies and technical analyses, this presentation examines the barriers to the integration of these tools into industry workflows, and in particular those preventing the mass production of topology optimized parts (such as cost and manufacturing constraints). We will demonstrate technical solutions which allow engineers to harness these tools across various sectors, enhancing value creation and efficiency for generalist engineers.
Presenter:
Christian Waldvogel
Organization:
Spherene
Spherenes
Spherenes, also called Adaptive Density Minimal Surfaces (ADMS), expand upon the well-known TPMS by being aperiodic and isotropic yet highly regular, inherently surface-conformal and, at the same time, freely configurable. Christian Waldvogel, who was an acclaimed artist, author and architect before founding spherene, will provide an insight into the spherene’s distinctive and unique properties as a metamaterial, and their straightforward application as an autonomous design tool in additive manufacturing.
Presenter:
Bradley Rothenberg and Markus Lempke
Organization:
nTop + Siemens Energy
Leveraging Computational Design with nTop to Drive the Energy Transition
The demand for energy worldwide is ever growing. At the same time the need to reach Carbon Net Zero requires technology shifts as well as drastic efficiency increases in existing infrastructure. In this talk we want to show some examples how Siemens Energy utilizes implicit modeling and computational design to help address these challenges. Furthermore we will give a glimpse into nTop computational models and how other customers are using implicit modeling to solve advanced design challenges. We’ll also present the new features that will further accelerate the adoption of computational design in energy applications and beyond.
AutomatiOn, optimization & Simulation
Presenter:
Daniel Siegel
Organization:
Synera
Process Automation for Engineers
Synera leverages visual programming to automate engineering processes, fostering agile hardware development while seamlessly connecting CAx tools and centralizing expertise across the organization.
Presenter:
André Wilmes
Organization:
Rafinex
Robust Designs – The role of Variability (UQ) in making Computational Design Optimization achieve reliable products that are fit-for-reality
André Wilmes has co-founded Rafinex to solve customers’ most challenging engineering design and optimization challenges with the most advanced mathematics. Rafinex creates novel algorithms which go beyond current market CAE tools by accounting for real-life variability using uncertainty quantification methods and by considering manufacturability; allowing safe and profitable usage by everyone in engineering design. André has researched numerical methods for simulating composite nano-materials at Imperial College London and has given guest seminars at leading research centers including NASA and TU Munich. He has experience as an R&D project manager in the ceramics and manufacturing industries, where he developed new simulation methods and experimental prototype processes in a variety of material topics ranging from fracture mechanics to optics.
Presenter:
David Heiny
CEO & Co-Founder
Organization:
SimScale
Enhancing Computational Design with Real-Time Design Insights Using AI & Physics Simulations in the Cloud
The advent of artificial intelligence (AI) in engineering simulation begins a transformative era in product development processes. This presentation outlines the substantial impact of AI adoption in engineering simulation, focusing on how AI models, trained using real and simulated engineering data , can significantly accelerate or even automate future engineering workflows.
SimScale is developing a pioneering platform in this domain, offering a solution that amalgamates AI with traditional CAE methods. This platform provides accessible tools for both designers and simulation experts, capturing the entire spectrum of AI-enhanced simulation processes and ensures AI future readiness. We present a case study of deploying AI through a cloud-native engineering simulation platform with global engineering teams in the automotive, manufacturing and AEC industries.
Keynote Presentation
Presenter:
Johannes Pauli
Research Engineer
Organization:
BMW Group
Group Inventions, Vehicle Concepts and Technologies
Industrial Challenges in Geometry Optimization for Additive Manufacturing
Laser powder bed fusion (LPBF) is considered to be one of, if not the, manufacturing technology with the biggest design freedom for structural metal AM parts. While this holds true, the part geometry does have a big influence on the cost and quality of components manufactured using LPBF.
To meet the economic requirements of the automotive industry, it is therefore not enough to optimize a part for mechanical performance only. Instead, the geometry needs to be optimized for manufacturing simultaneously. At BMW, an optimization procedure has been developed to achieve both good mechanical performance as well as a good manufacturability. It involves topology optimization with the objective to reduce weight, and thus material use, as a first step. Afterwards, the resulting geometry is modified using free-form shape optimization to achieve an overhang-free design with good nestability, that fulfills the mechanical requirements of the part.
By applying the presented optimization procedure, more parts with less support structure and less material use can be manufactured in the same build volume. This results in lower manufacturing costs, as labor and material cost per part is reduced. Selected example parts that are now being used in series production are shown. Without consideration of manufacturing requirements for additive manufacturing in the geometry optimization, these components would not have been economical for series production using LPBF.
As a further outlook, the Wire Arc Additive Manufacturing (WAAM) technology will be discussed. On one hand, it has a high potential regarding machine cost and material deposition rate, compared to LPBF. On the other hand, there are many challenges yet to be addressed, e.g. surface quality and manufacturing constraints for the geometry generation process.
First studies have been carried out using existing commercial software to generate WAAM parts. However, the functionality at this point is not sufficient, resulting in many manual design iterations to create parts that meets both manufacturing as well as functional requirements at competitive cost.
Presenter:
Leon Tillmann
Organization:
BERLIN PARTNER FOR BUSINESS AND TECHNOLOGY GMBH
Why is Berlin the top address for AM in Europe?
Berlin is already known for offering the perfect environment for AI startups and software companies. We at the AM cluster AMBER believe that by bringing them together with the numerous players in Berlins AM ecosystem, we can unleash the full potential of the technology right here in the heart of Europe.
Wednesday May 8th 2024
From Perfection to production
Presenter:
Prof. Ole Sigmund
Organization:
TECHNICAL UNIVERSITY OF DENMARK
Perfect designs for imperfect AM
Ole Sigmund is a Danish Professor in Mechanical Engineering who has made fundamental contributions to the field of topology optimization, including microstructure design, nano optics, photonic crystals, Matlab code, acoustics, and fluids.
Read an Interview with Prof. Ole Sigmund from 2022 and his thoughts on AI for Topology Optimisation in 2024
Presenter:
Dr. Nick Simpson
Organization:
UNIVERSITY OF BRISTOL
Metal Additive Manufacturing in Power Electronics, Machines and Drives: Opportunities and Challenges
The electrification of transport, in pursuit of Carbon Net Zero, is driving demand for a step change in the power-density of electrical machines. A viable route is to exploit the geometric freedom of metal additive manufacturing to realise next-generation electrical windings enabling targeted electromagnetic loss mitigation, integrated thermal management, and high-temperature insulation coatings. This talk will present some of the latest advances in the field of Additive Manufacturing in Electrical Machines and discuss some of the ongoing computational design challenges that the CDFAM community may be able to help with.
Presenter:
Chelsea Cummings
Organization:
The Barnes Global Advisors
Design Parts Not Shapes
3D printing is dead. Like a once shiny child star, the hype has tapered and it’s time to grow up. Thankfully, it is officially out of its awkward teenage years and has graduated into adulthood as AM. 3D printing established a microeconomy built on venture capitalism, but now that the sensationalism wanes, how does the industry achieve the returns it has promised? Understanding AM’s fit in the manufacturing ecosystem is key, and it has always revolved around the same thing. Parts. 3D printing made shapes, it’s time to additively manufacture parts; and that starts with design.
Read the Interview with Chelsea Cummings
Presenter:
Peter Clausen & Pascal Hebrard
Organization:
Dassault Systemes
Computational Design For Conventional Manufacturing
Dassault Systèmes (3DS) and the 3DEXPERIENCE® Platform provides the principal platform for MODSIM integrating modeling, simulation and optimization. In 2016, 3DS uniquely released CATIA Function Driven Generative Designapplication, which integrates topology optimization and CAD-reconstruction of the new geometry in a single application. Since then, multiple applications have been released with focus on generative design using other non-parametric optimization methods like shape, bead and sizing. Additive manufacturing (AM) was the initial driver of these developments, but the later years also have focused more on classic manufacturing methods like casting, milling and stamping. The common denominator for all these End-To-End workflows is that they start from a CAD-model and the result is a new CAD-model. We will present state-of-the-art End-to-End workflow with focus on conventional manufacturing, which for most industries is still far more important than additive manufacturing.
multi-objective optimisation at architectural scale
Presenter:
Verena Vogler
Organization:
McNeel Europe
Ecological Analysis of Building Envelopes
Verena Vogler, head of R&D at McNeel Europe, will be presenting an innovative framework and ecological analysis tool within Rhino for designing building envelopes that prioritize the needs of non-human inhabitants. The approach is developed in the ECOLOPES project funded by the European Commission.
Presenter:
Preety Anand
Organization:
Raumfachwerk
Preety Anand is an architect & computational designer with experience on working on large scale and complex projects set in diverse contexts. Her noteworthy experiences include parametrically modelling façade systems, rationalizing complex geometry and investigating on the aspect of interoperability. Her goal is to develop holistic computational design tools and workflows which continuously adjust responding to the specific needs of the phase.
She is currently working as an architect and computational designer on the geometrically complex and space defining timber structure of the Zurich Airport.
Presenter:
Gabriel Garcia
Organization:
Computational Design and Machine Learning in MEP Systems for Large-Scale Architecture
Using computational design and machine learning to optimize large-scale building designs, drawing parallels between building structures and the human body. It emphasizes the essential role of Mechanical, Electrical, and Plumbing (MEP) systems, akin to a building’s vital organs. The focus is on enhancing MEP installations’ efficiency, thereby reducing energy demands and carbon footprint, crucial in sustainable architecture. The presentation will cover three key areas: optimizing ventilation ductwork to reduce spatial volume, employing 3D pathfinding for efficient data cable network layouts, and achieving optimal Wi-Fi coverage with minimal hardware. These strategies aim not only for sustainability but also for reduced construction and maintenance costs, marking a step towards more environmentally responsible architectural practices.
Presenter:
Rick Titulaer
Organization:
Informed Data-Driven Computational Design
The renovation of the Santiago Bernabéu Stadium in Madrid has recently been completed. The stadium’s extensive history and renovation posed unique design challenges, particularly in addressing and analysing reflections caused by the new metallic façade. In response to this challenge, a computational design approach was employed to analyse over 682,000 different configu-rations, facilitating an informed data-driven decision-making process.
The case study details the methodology, workflow, and analysis process. It describes the generation of a parametric model of the façade elements and the use of sun path data and architectural context to assess glare. To manage the computational complexity, parallel computing was applied, and a custom script was utilized for the analysis. The outcomes of this data-driven approach revealed key areas of interest on the stadium’s façade and identified the most optimal angles to minimize glare. The study also highlights the rationalization process, including the use of Gaussian equations and number smoothening to create a smooth, glare-reducing surface. The final façade geometry was generated through iterative exploration, rationalization, and collaboration. This case study underscores the significance of data-driven computational design in overcoming complex design challenges, as demonstrated in the transformation of the Santiago Bernabéu Stadium’s façade.
from microstructure to metamaterials
Presenter:
Joseph Flynn
Organization:
Altair
Implicit Modeling that is user-friendly and expressive, without limiting flexibility
Joseph Flynn is a Software Development Architect at Altair, working on the algorithmic design and user experiences for Implicit Modeling within Altair Inspire. Prior to working at Altair, Joseph was an Associate Professor at the University of Bath, and one of the Co-Founders of Gen3D Ltd., which was acquired by Altair in 2022. His major focus is the R&D strategy for future features within Inspire Implicit Modeling, and the wider integration of this technology across Altair products. He has recently been working on the trade-offs and interplay between automated computational design and traditional computer-aided design. In the former, geometry emerges and, in the latter, geometry is constructed/sculpted. The balance between these two approaches will be the subject matter for Joseph’s presentation.
Presenter:
Elissa Ross
Organization:
Metafold
Geometric Infrastructure for Additive Manufacturing
Infrastructure consists of the basic physical and organizational structures needed for the operation of a system. 3D printing has highlighted cracks in the foundations of the geometric infrastructure for digital manufacturing, illustrated by time-consuming workflows, bloated file sizes, and projects that can’t get off the ground or never see commercialization.
Geometric infrastructure for additive manufacturing must be optimized for ease of integration to deliver the key benefits of additive manufacturing, namely optimized designs and automated customization. We illustrate the impact of an API-first approach to software tooling for additive manufacturing through several case studies.
Presenter:
Alexander Pluke
Organization:
Additive Flow
Additive Flow
Alexander Pluke is CEO and founder of Additive Flow, a Nano Dimension Division. The company builds software for the simultaneous optimisation of the entire AM workflow, which has worked with companies including Saint-Gobain, Royal Haskoning, Tata Steel and Zeiss to maximise their AM value.
Presenter:
Omar Fergani
Organization:
1000Kelvin
How AI copilot are enabling the AM industry scaling: A case study
Omar is CEO and co founder of 1000 Kelvin, he is a holder of Ph.D. in Mechanical Engineering and an expert in digital manufacturing. Omar held various executive positions at Siemens and MKS Instruments including director of strategic business, Senior Director of Digital platforms and product management lead. His expertise and contributions to the industry were recognized when he was honored as the SME Outstanding Young Engineer in 2019.
Deus ex Machina
Presenter:
Kristen M. Edwards
Organization:
Massachusetts Institute of Technology’s DeCoDE Lab
Concept to Manufacturing: Evaluating Vision-Language Models for Engineering Design
Engineering Design is undergoing a transformative shift with the advent of AI, marking a new era in how we approach product, system, and service planning. Large language models have demonstrated impressive capabilities in enabling this shift. Yet, with text as their only input modality, they cannot leverage the large body of visual artifacts that engineers have used for centuries and are accustomed to. This gap is addressed with the release of multimodal vision language models, such as GPT-4 with vision, enabling AI to impact many more types of tasks. In light of these advancements, this work presents a comprehensive evaluation of GPT-4 with vision across a wide spectrum of engineering design tasks, categorized into four main areas: Conceptual Design, System-Level and Detailed Design, Manufacturing and Inspection, and Engineering Education Tasks.
Presenter:
Matthias Bauer
Organization:
Navasto
AI Accelerated Engineering
Design in real-time, optimize your product, and reduce costs with unlimited iterations.
Read the interview with Matthais Bauer
Presenter:
Manolis Papastavrou
Organization:
METAMORPHIC AM
CDfAM at the Service of Emerging Technologies – Innovating with AM in Quantum Technologies
Manolis Papastavrou is the co-founder and Computational Design Lead at Metamorphic, a UK based design engineering consultancy that helps organisations innovate with Additive Manufacturing (AM). His presentation will demonstrate how the team at Metamorphic harness computational design to exploit untapped possibilities for AM in a range of technology sectors. This will be illustrated through one of their latest collaborative projects in the field of Quantum Sensing, Project QTEAM (Quantum Technologies Enabled by Additive Manufacturing). QTEAM seeks to revolutionise the design and manufacturing of ultra-high vacuum (UHV) components to enable a new “ultra-portable” phase of quantum technologies for space applications. Manolis will provide insights into Metamorphic’s design-to-manufacturing workflows and how these have been automated through purpose-built computational design scripts. We will delve into the intricacies of their design process, the challenges they’ve overcome, and the innovative solutions they’ve employed in their quest to produce a lightweight and power-efficient quantum space gravimeter prototype.
Closing Keynote Presentation
Presenter:
Onur Yüce Gün
Organization:
New Balance
Shape of Generative AI
This presentation speaks of computation and design, exploring the depths of machine intelligence and the philosophy of being.
The aim is to empower the audience with tools so they can navigate the effects of computational design thinking across the disciplines of Architecture Engineering and Construction, product design, and visual arts, and develop strategies to take insightful steps amid fast-developing AI technologies.
Presentations without recordings
Presenter:
Duann Scott
Organization:
CDFAM
Welcome to CDFAM Berlin
Duann Scott, founder of the CDFAM Symposium Series will provide opening remarks on a computational design landscape in the context of additive, and advanced manufacturing.
Computational Design Paradigms
Presenter:
Federico Casalegno
Organization:
Samsung
Opening Remarks
Opening Remarks by Federico Casalegno, Head of Samsung Global Design Strategy & Global Design Studios
Presenter:
Patrick Pradel
Organization:
LOUGHBOROUGH UNIVERSITY + UK DESIGN FOR AM NETWORK
Is Additive Manufacturing Transforming Design into Computational Design?
This is a provocative presentation in which I want to present the results of the When Design Never Ends project and discuss with the audience if and how Additive Manufacturing and Computational design tools are transforming Design. Additive Manufacturing can make shapes that would be impossible, or at least very expensive, to make with traditional manufacturing methods. However, to harness this freedom and develop innovative and performant products, designers need to be able to conceive and design extremely elaborate and intricate geometries. These geometries are challenging to achieve with traditional design tools and processes and they in most circumstances, only be achieved by using computational design tools. This seems to be driving the establishment of computational designers.
During the When Design Never Ends project we interviewed over 20 professional designers and compared “traditional” versus “computational” design practices. The insights from the project show the similarities, but most importantly the differences between these two “approaches” to designing physical artifacts. This is quite interesting since it raises the question of whether these are becoming separate disciplines (or if they have ever been separate) or if one is the evolution of the other (are designers destined to become computational?). Moreover, it raises questions on design education, job prospects and skills requirements.
Aaron Porterfield
Presenter:
Organization:
F=F
Crystallon
Crystallon and the Journey from Industrial Design to Computational Design
From the humble beginnings of Blender and Reprap, to Grasshopper and Crystallon. Designing products, to designing tools and workflows, and how a wide variety of clients and projects have come along the way. From from shoes to pavilions. And how the open-source community, and knowledge sharing have been the driving force behind it all
If you are interested in participating in future events we accept submissions year round and are always interested in innovative projects in the computational design space.
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