Clemson University optimizes metal 3D printing with modeFRONTIER
modeFRONTIER helped the Clemson CEDAR group optimize the process parameters in Direct Metal Deposition (DMD) Fabrication Process - a 3D printing process for metal, similar to welding, using powders instead of wire.
Jingyuan Yan, Ph.D in Department of Mechanical Engineering at the Clemson University, used modeFRONTIER to develop his Ph.D research project focused on the design and optimization of the DMD process. Jingyuan worked on the design of the injection nozzle to maximize the process efficiency and investigate the relationship between the desired part’s composition and the process parameters.
“We aimed at optimizing the process parametres in order to make the best use of powders and to minimize the laser energy consumption. The bi-objective optimization problem was set up in the modeFRONTIER workflow using the direct node to MATLAB. Eight design variables related to the process parameters (injection angles, velocities and nozzle diameters for the two materials as well as the laser power and the scanning speed) were set and automatically adjusted with modeFRONTIER to minimize the outputs: powder waste and energy cost.”
“The calculation process took about three hours. With modeFRONTIER, we saved about three days of calculation time compared to the traditional optimization method".