Optimization-based Design for Manufacturing

Abstract

This work comprehensively documents the development and integration of advanced optimization algorithms within the Plato software to enable optimization-based design for additive manufacturing. It details the implementation of forward and adjoint finite element solvers for simulating elastoplastic and thermo-elastoplastic physics, which are used within a design optimization framework to predict the residual stress tensor at every material point. Design criteria were formulated and implemented to minimize residual stress in additively manufactured components, enhancing structural performance and reliability. Additionally, this work presents topology and shape optimization algorithms tailored for additive manufacturing, supported by numerical examples demonstrating their application. The documented methodologies and results provide valuable insights into leveraging computational design optimization for improving additive manufacturing processes.

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Morphorm® is an emerging leader in engineering simulation and modeling technologies. Founded in 2022 and headquartered in Albuquerque, New Mexico, Morphorm is advancing state-of-the-art optimization and simulation technologies to drive product innovation in clean energy, semiconductors, and defense. The company’s pioneering real-time design solutions are setting new industry benchmarks in performance and efficiency.

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