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3D PRINTING
they need to balance the manufacturing parameters to meet the functional requirements. Virtual testing allows users to validate part strength and stiffness by identifying anchor and load surfaces. Users can enter the required values for loads, safety factors and maximum deflection into the software, which then produces a multitude of options they can choose from. Applying their judgment and experience, engineers can then decide which solution will ultimately create the part best suited to addressing the specific problem they are trying to solve.
In other words, feedback the validation process empowers engineers to build the best possible part to meet their requirements. It provides a number of options to choose from for optimising the part based on cost savings, material usage, print time, strength or stiffness. By providing a complete description of how the part will perform after it is built, Simulation and virtual testing take the guesswork out of the equation. They instil the all-important confidence that CAD and CAE cannot – as yet – provide, encouraging engineers to be bold in the knowledge that the part they print the first time can withstand the rigorous demands of industrial applications.
SPEEDING UP CUSTOMISATION WITH LARSEN MOTORSPORTS US-based Larsen Motorsports builds jet engine drag racing vehicles that reach speeds beyond 280mph. To ensure safety at such velocities, each driver needs their own custom steering wheel that can withstand more than 180 pounds (approximately 82kg) of force pulling on one side at any given time. Performing in these demanding conditions inevitably leads to the need for regular replacements, but with limited storage space and a lead of eight or more days, using traditionally manufactured methods was not a viable option for the team. Fuelled by the need to cut lead times without compromising on safety led Larsen
Motorsports to work with Markforged to explore alternative routes for their drivers’ bespoke steering wheels. To test and iterate the design, they ran the design specs of rookie driver Josette Roach’s bespoke aluminium steering wheel through its Simulation software, allowing them to arrive at the right strength, size and stiffness to meet Roach’s rigorous requirements – and to print a Continuous Carbon Fibre reinforced Onyx steering wheel strong enough to replace her aluminium one. “I trust the steering wheel with my life,” says Roach.
The whole process took only two days, eliminating the need to print multiple part designs. Brian Tocci, director of Operations, Larsen Motorsports notes, “We don't have to print 10 different parts. We can do it all in Simulation."
EXPLORING ALTERNATIVE MATERIALS The team at Larsen Motorsports were also able to investigate and understand the performance of different materials using Simulation software. For example, by mapping out precisely where
carbon fibre reinforcement is needed (and where it is not), specific parts can be strengthened without the need for additional weight. This level of detail and visibility can make pricier materials like CF a viable alternative to lightweight metals like aluminium, empowering engineers to better understand how to make the most of materials in AM to support both design and budget requirements.
THE POWER OF THE CLOUD Validation requires computing power and running simulations across cloud-based software, spreads the load across multiple machines, which helps avoid bottlenecks and speed up the process. The cloud also provides the ability to interrogate a wider bank of knowledge and data, apply it to each build and feed it back into the design and build loop. This process allows the software simulation to continue to learn and evolve. It improves the experience for engineers that use it, instilling greater confidence in the process and, ultimately, the performance of each part they print.
Markforged
markforged.com
UKManufacturing Summer 2023
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