In the aerospace field, the Korea Aerospace Research Institute (KARI) has successfully applied the Materialise 3-matic software, combined with the DfAM (Design for Additive Manufacturing) process, to create lattice structures that reduce weight and increase the durability of critical components. This has provided an effective solution for additive manufacturing.
Introduction to Materialise 3-matic software
In the realm of 3D design and printing, Materialise 3-matic stands out for its ability to optimize and control the design of complex structures such as lattice structures. This software not only assists in creating highly accurate 3D models but also enables engineers to convert designs into STL files ready for 3D printing. It is particularly useful in industries with stringent requirements, like aerospace.
Lattice structure – An effective weight reduction solution
Lattice structures are mesh-like designs that reduce the weight of components while maintaining strength and stability. In 3D printing, lattices are used to minimize material consumption without compromising the product’s durability. This structure is especially important in the aerospace industry, where components must be lightweight yet still meet strict safety and strength requirements.
Lattice structures optimize material usage and weight when producing load-bearing components
Challenges in designing lattice structures
Challenge 1: Topology optimization and surface smoothing
Applying lattice structures requires engineers to not only create a lightweight design but also ensure it can be 3D printed without compromising structural integrity. This was the challenge KARI faced when researching and developing parts for the landing gear of aircraft.
In a previous study, Dr. Kim Tae-wook, from KARI’s Aeronautics Research Directorate, used Altair® OptiStruct software to convert simulation test results into a 3D model. The part was successfully printed with the support of an external service provider. However, when continuing to reduce the part's weight, Dr. Kim encountered challenges in optimizing the topology and smoothing the surface while retaining the lattice structure.
Challenge 2: Converting to an STL file
The second issue Dr. Kim faced was converting the 3D model into a printable STL file. Although the new model used a lattice structure to minimize material usage, the conversion process was problematic. When attempting to re-run simulations of the model, Dr. Kim realized the need to optimize the design and ensure that the STL file could be printed in metal without breaking the lattice structure during the printing process.
KARI's first metal 3D-printed landing gear component
While KARI’s initial metal structure was reliable, the team aimed to further reduce its weight by incorporating a lattice structure. However, converting the raw lattice data into a printable file required software that allowed full control over the process.
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Solution: Materialise 3-matic and DfAM
To address these challenges, KARI used Materialise 3-matic, a specialized software that supports DfAM. This software offers advanced features to optimize the design process, ensuring that the printed product has a smooth surface and avoids weak points within the lattice structure.
Benefits of using Materialise 3-matic
- Topology Optimization: 3-matic helps optimize the geometry of the model, ensuring smoother surfaces and preventing breakage during 3D printing.
- Complete STL File Creation: The software can convert complex lattice models into printable STL files, resolving issues related to surface thickness and avoiding interactions between support materials and the lattice.
- Full Control Over Lattice Details: Materialise 3-matic allows full control over lattice structures, optimizing the printability of the product while maintaining its structural integrity.
With the support of 3-matic, KARI's research team successfully reduced the weight of aircraft landing gear components while maintaining structural stability. The completed 3D-printed product was not only lighter but also more reliable than previous designs.
3D-printed landing gear components after applying lattice structures
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Results of applying 3-matic in aerospace projects
The use of Materialise 3-matic not only helped KARI reduce trial-and-error experiments but also enabled them to achieve their desired results more quickly. The software has proven effective in creating lightweight, reliable 3D-printed parts, especially for complex aerospace applications.
Thanks to 3-matic, KARI has made significant strides in reducing weight and optimizing designs while ensuring the durability of their 3D-printed products. Impressed by the results, KARI is now undertaking new projects using this software.
Reference: KARI Optimizes and Converts 3D Lattice with Materialise 3-matic
Conclusion
Materialise 3-matic is a powerful tool for engineers and designers looking to apply 3D printing technology to complex projects, particularly in the aerospace industry. With its ability to optimize lattice structures and convert them into printable STL files, 3-matic provides the perfect solution for reducing weight, increasing stability, and ensuring manufacturability.
If you're searching for a 3D design software solution to optimize lattice structures and achieve precise 3D printing, Materialise 3-matic is undoubtedly a top choice.
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