ParaMatters is a fully autonomous and intuitive generative design and simulation platform that optimizes the most labor-intensive steps in the digital work flow from design to manufacturing. We deliver the best-in-class lightweighting and performance enhancements with ready to manufacture designs in a short period of time without manual interruption or re-modeling.
Advanced Additive Manufacturing expands into multi-material, hence there is a need for efficient multi-material design software tools. Apparently, there is a lack of multi-material design solutions on the market and this gap must be filled. ParaMatters does the job.
What would we expect from such a generative design software? Ideally, such a tool should provide with optimal structures having most effective distribution of topology and material type simultaneously. This is a very challenging problem, because each candidate material has different material properties, like density, stiffness, strength etc. In optimal structures, a strong material should be located in places where stresses are high while a weak material can be located in moderate stressed areas. Stronger materials are usually heavier or more expensive, hence ideally a designer would be interested in the cheapest and/or lightest solution.
Multi-Material Generative Design technology developed by ParaMatters to allow significant reduction in weight and manufacturing cost.
Natural structures, which evolved millions or billions of years are optimal to carry set of applied loads. For us, humans it is not always clear what are the loading conditions, but we can have an educated guess. Looking closer into bone micro-structure we can clearly see that:
Are we able to generate optimal porous structures which would mimic natural structural behavior?
ParaMatters Meso-Structural Design Technology makes it possible.
How such designs would look like in 3D? First, switching from 2D to 3D is computationally challenging. We expect to have very detailed designs, which are reflected into high-resolution Finite-Element models. Thanks to ParaMatters unique technology, large-scale Topology Optimization problems can be solved. Typically, 10-60 Million 3D-elements (30-180 Million Degrees of Freedom) can be easily and effectively solved using ParaMatters solvers. This resolution is not a limit, hundreds of millions of elements resolution can be achieved.
In order to demonstrate 3D optimal porous design in meso-structural level, we will consider femur bone case under two loading cases.
This is clear that meso-structural designs are redundant to localized failure, means if there is a given member failure an alternate load path occurs. This approach is ideal for secondary-load path or fail-safe design philosophy which applied in critical aerospace applications.
Is such a complex design manufacturable? The design is available as mesh (STL, PLY) and can be Additively Manufactured in spite of the tremendous complexity. Volumetric representation is also possible:
The optimal porosity changes due to the applied loading direction. This design approach is much more optimal and viable than replicating periodic lattice unit cell. Let’s have an example: