|Published on:||May 17th, 2021|
|With:||Eric Miller, Tyler Smith & Connor Nail|
In this episode your host and Co-Founder of PADT, Eric Miller is joined by Tyler Smith and Connor Nail from the ASU Luminosity Lab to talk about their recent presentation at Ansys Simulation World 2021. A team of students at the ASU Luminosity Lab was awarded funding from NASA to develop a system for exploration of the permanently shadowed regions of the lunar poles.
Through this project titled VELOS (Variable Exploratory Lunar Observation System) the team designed, built, and conducted proof-of-concept testing to successfully validate operation of their prototype system. Learn how Ansys helped make their success possible.
If you have any questions, comments, or would like to suggest a topic for the next episode, shoot us an email at email@example.com we would love to hear from you!
PADT is currently partnering with Arizona State University’s 3DXResearch group on exploring bio-inspired geometries for 3D Printing. As part of that effort, one of our engineers involved in the project, Alex Grishin, PhD, was a co-author on several papers that have been published during this project.
Below is a brief summary from Alex of each article, along with links.
PADT participated in the research with the above title recently published in the open-access online journal MDPI ( https://www.mdpi.com/1996-1944/12/20/3455/htm ). This work was funded by the America Makes Program under a project titled “A Non-Empirical Predictive Model for Additively Manufactured Lattice Structures” and is based on research sponsored by the Air Force Research Laboratory under agreement number FA8650-12-2-7230.
Current ASU professor and former PADT employee Dhruv Bhate was the Lead Investigator and wrote the original proposal. Dhruv’s research interests involve bio-inspired design (the study of structures found in nature to help inform human design efforts) and additive manufacturing. Dhruv is particularly interested in the bulk properties of various lattice arrangements. While investigating the highly nonlinear force-deflection response of various additively manufactured honeycomb specimens under compression, Dhruv discovered that polymer and composite honeycombs showed extreme sensitivity to strain rates –showing peak responses substantially higher than theory predicts at various (low) strain rates. This paper explores and quantifies this behavior.
The paper investigates hexagonal honeycomb structures manufactured with four different additive manufacturing processes: one polymer (fused deposition modeling, or material extrusion with ABS), one composite (nylon and continuous carbon fiber extrusion) and two metallic (laser powder bed fusion of Inconel 718 and electron beam melting of Ti6Al4V). The strain rate sensitivities of the effective elastic moduli, and the peak loads for all four processes were compared. Results show significant sensitivity to strain rate in the polymer and composite process for both these metrics, and mild sensitivity for the metallic honeycombs for the peak load.
PADT contributed to this research by providing ANSYS simulations of these structures assuming viscoplastic material properties derived from solid dog-bone test specimens. PADT’s simulations helped provide Dhruv with a proposed mechanism to explain why INSTRON compression tests of the honeycomb structures showed higher peak responses (corresponding to classical ultimate stress) for these specimens than the solid specimens.
PADT participated in the NASA-funded research with the above title recently published in the open-access online journal MDPI (https://www.mdpi.com/2313-7673/5/4/59/htm ). This work was guided by former PADT engineer and current ASU Associate Professor Dhruv Bhate. Professor Bhate’s primary research interests are Bio-Inspired Design and Additive Manufacturing. It was only natural that he would secure a grant for this research from NASA’s Periodic Table of Life ( PeTaL) project. To quote from the website, “the primary objective…is to expand the domain of inquiry for human processes that seek to model those that are, were or could be found in nature…”
This paper focuses on the morphology of bee honeycombs found in nature –the goal being to identify key characteristics of their structure, which might inform structural performance in man-made designs incorporating similar lattice structures. To this end, the paper identifies three such characteristics: The honeycomb cell corner radius, the cell wall “coping” (a localized thickening of the cell wall at the mouth of each cell seen in a lateral cross-section), and the cell array “interface” (a zigzag pattern seen at the interface of two opposing, or “stacked” arrays).
Most of this work involved material testing and measuring dozens of natural honeycombs (most coming from various museums of natural history found in the United States) at ASU’s state-of-the-art facilities. PADT contributed substantially by verifying and guiding tests with simulation using the ANSYS suite of software.
PADT participated in this research found in the reviewed article published in Proceedings of the 29th Annual International Solid Freeform Fabrication Symposium – An Additive Manufacturing Conference.
The lead investigator was current ASU professor and former PADT employee Dhruv Bhate, whose research interests involve Bio-Inspired Design (the study of natural structures to help inform human design processes) and Additive Manufacturing. In this research, Dhruv investigates discrepancies between published (bulk) material properties for the Fused Deposition Modeling (FDM) of ABS honeycomb structures. The discrepancies arise as substantial differences between published material properties, such as Young’s Modulus and yield stress, and those determined experimentally from FDM dog-bone specimens of the same material (which he refers to as “member” properties).
PADT’s role in this research was crucial for demonstrating that the differences in base material characterization are greatly exacerbated in nonlinear compression simulations of the ABS honeycomb structures. PADT used both the manufacturer’s published properties, and the dog-bone data to show substantial differences in peak stress under the two assumptions.
We are very pleased to announce that PADT is part of another successful Federal grant with ASU in the area of Additive Manufacturing. This is the second funded research effort we have been part of in the past twelve months and also our second America Makes funded project.
It is another great example of PADT’s cooperation with ASU and other local businesses and also shows how Arizona is becoming a hub for innovation around this important and growing technology.
You can find links to our other recent research grants here:
If you have any questions about, additive manufacturing or this project, reach out to firstname.lastname@example.org or call 480.813.4884.
For as long as PADT has been involved in Additive Manufacturing, we have been interested in how the process of building geometry one layer at a time could be used to more closely represent how nature creates objects. Nature is able to create strong, lightweight, and flexible structures that can not be created using traditional ways of manufacturing like machining, molding, or forming. 3D Printing gives engineers and researchers the ability to explore the same shapes that nature creates.
As you can imagine, strong and light structures are very beneficial for objects that need to be launched into space. That is why NASA just awarded PADT and Arizona State University, a Phase 1 STTR grant to explore how to make just this type of geometry. We are excited to work with ASU to define what the possibilities are in this first phase and then apply for a Phase 2 grant to bring real-world applications of this technology to industry.
This is PADT’s 14th SBIR/STTR and our second joint project with Dr. Dhruv Bhate at ASU. Many of you may remember the research and process improvements that Dhruv worked on when he was a PADT employee. We look forward to sharing our results with the Additive Manufacturing community and moving this exciting application for the technology forward.
If you have any questions about high-performance computing for simulation, either with local hardware or compute resources in the cloud, reach out to email@example.com or call 480.813.4884.
Sometimes we run across some great exampls of industry and academia working together and like to share them as examples of win-win partnerships that can move technology forward and give studends a great oportunity. A current Capstone Design Project by students at ASU Polytechnique is a great example. It is also an early exmple of what can be done at the brand new Additive Manufacturing Center that was recently opened at the campus.
I’ll let ASU Mecanical Enginering Systems student Dean McBride tell you in his own words:
Orbital ATK in Chandler currently utilizes two Stratasys Dimension SST 1200es printers to prototype various parts with. These printers print on parts trays, which must be removed and re-inserted into the printer to start new prints. Wanting to increase process efficiency, Orbital had the desire of automating this 3D printing process during times when employees are not present to run the printers. After the idea was born, Orbital presented this project to ASU Polytechnic as a potential senior capstone design project. Shortly after, an ambitious team was assembled to take on the project.
Numerous iterations of the engineering design process took place, and the team finally arrived at a final solution. This solution is a Cartesian style robot, meaning the robot moves in linear motions, similar to the 1200es printer itself. The mechanical frame and structure of the robot have been mostly assembled at this point. Once assembly is achieved, the team will focus their efforts on the electrical system of the robot, as well as software coding of the micro-controller control system. The team will be working to fine tune all aspects of the system until early May when the school semester ends. The final goal of this project is to automate at least two complete print cycles without human interaction.
Here is a picture of the team with the robot they are building along side the Stratasys FDM printer they are automating.
There is something about a kid running down a hallway screaming “mom, you HAVE to see this!” #openhousegoals.
Last night was our annual event where we open up the doors of PADT with a family oriented event sharing what we engineers do. We also invited some students from high school and University to share their engineering activities. With over 250 attendees and more than one excited kid running down the hall, we can safely call it a success.
Attendies were able to see our 3D Printing demo room including dozens of real 3D printed parts, learn about engineering, explore how 3D Printing works, and check out our new metal 3D Printer. They were also able to learn about school projects like the ASU Formula SAE race car as well as a prosthetic hand project and research into cellular structures in nature from BASIS Chandler.
Oh, and there was Pizza.
Pictures speak louder than words, so here is a galary of images from the event.
Two weeks ago we were part of a fantastic open house at the ASU Polytechnic campus for the grand opening of the Additive Manufacturing Research center, a part of the Manufacturing Research and Innovation Hub. What a great event it was where the Additive Manufacturing community in Arizona gathered in one place to celebrate this important piece in the local ecosystem. A piece that puts Arizona in the lead for the practical application of 3D Printing in industry.
I could go on and on, but better writers by far have penned some great stories on the event and on the lab.
And Hayley Ringle of the Phoenix Business Journal summed it all up, with some great insight into the impact on education and job growth in “See inside the Southwest’s largest 3D printing research facility at ASU”
And last but not least, here are some pictures related to PADT that ASU provided:
On January 18th, ASU will officially Launch their Manufacturing Research and Innovation Hub, the Largest Additive Manufacturing research and teaching center in the Southwestern US. PADT is proud to have partnered with ASU as well as with Concept Laser and Honeywell to get this important piece of the local manufacturing ecosystem started and to keep it growing.
Located on the Polytechnic School at ASU in Mesa, Arizona, this facility is amazing. And you can see it for yourself, the public is invited to the launch on January 18th, 2017 at 9:00 am. ASU Polytechnic Dean Kyle Squires and the Director Ann McKenna will be speaking as will our very own Rey Chu, John Murray from Concept Laser, and Don Godfrey from Honeywell. Tours will follow. Learn more and register for this free event that will bring together the local 3D Printing community here.
You can also learn more by reading the official press release from Concept Laser that outlines what the center does and the partnerships that make it possible:
The resent launch of OSIRIS-REx probe to visit the asteroid Bennu was a milestone for Arizona. In “Arizona solidifies position as a leader in space technology” I review how ASU, UofA and Tempe’s Kinnetx played a key role in device design and development as well as mission and scientific control.
Over the past two academic semesters (2015/16), I had the opportunity to work closely with six senior-year undergraduate engineering students from the Arizona State University (ASU), as their industry adviser on an eProject (similar to a Capstone or Senior Design project). The area we wanted to explore with the students was in 3D printed lattice structures, and more specifically, address the material modeling aspects of these structures. PADT provided access to our 3D printing equipment and materials, ASU to their mechanical testing and characterization facilities and we both used ANSYS for simulation, as well as a weekly meeting with a whiteboard to discuss our ideas.
While there are several efforts ongoing in developing design and optimization software for lattice structures, there has been little progress in developing a robust, validated material model that accurately describes how these structures behave – this is what our eProject set out to do. The complex internal meso- and microstructure of these structures makes them particularly sensitive to process variables such as build orientation, layer thickness, deposition or fusion width etc., none of which are accounted for in models for lattice structures available today. As a result, the use of published values for bulk materials are not accurately predictive of true lattice structure behavior.
In this work, we combined analytical, experimental and numerical techniques to extract and validate material parameters that describe mechanical response of lattice structures. We demonstrated our approach on regular honeycomb structures of ULTEM-9085 material, made with the Fused Deposition Modeling (FDM) process. Our results showed that we were able to predict low strain responses within 5-10% error, compared to 40-60% error with the use of bulk properties.
This work is to be presented in full at the upcoming RAPID conference on May 18, 2016 (details at this link) and has also been accepted for full length paper submission to the SFF Symposium. We are also submitting a research proposal that builds on this work and extends it into more complex geometries, metals and failure modeling. If you are interested in the findings of this work and/or would like to collaborate, please meet us at RAPID or send us an email (firstname.lastname@example.org).
How do you turn a political defeat into a big win, you look at your options, decide where you want to go, and you do it. That is what a group of valley visionaries did in the early 1980’s when the state decided that only the University of Arizona could should have an agriculture program. That left Arizona State University with a large working farm that needed to be taken down. They could have sold the land for quick profit. But instead they looked at options that would provide the most long-term benefit to the school, the state, and the local community.
The result, thirty years ago, was the ASU Research Park. Located just west of the 101 Loop between Warner and Elliot roads, the Park is now a vibrant and thriving hot-spot of technical innovation and realization. This is not an incubator where people try to be successful in technology, this is where people who are successful with technology come to get stuff done.
PADT is pleased to own a building in the Park, the PADT Innovation Center, where our headquarters are located along with three other business that lease space from us. We have found the park to be a supportive place, centrally located, with great facilities for our employees.
The event was marked with a breakfast gathering of tenants, Tempe officials, Park board members, and representatives from ASU. Dr. Michael Crow, the President of ASU gave a great speech on how the park in particular helped move ASU towards being a true research university. He stressed that unlike in most places, ASU didn’t plan and study and move slowly. They wanted to become a research university and if you want to be a research university, you need a research park. So they built a research park, and in the end, a very successful one.
Some interesting facts about the park:
The mayor of Tempe, Mark Mitchel, was also on hand to share with the audience the strong impact that the park and ASU have had on the city and how the ASU Research Park is a true university-city initiative. In fact, Mr. Mitchel’s father, Harry Mitchel, was the mayor of Tempe thirty years ago and was one of the visionaries that helped make the park happen.
This aerial view, taken a few months ago, shows the new GoDaddy tech center being built in the lower right hand corner. The PADT innovation center is the upside-down check mark in the upper right corner. PADT customers ViaSat and Amkor are both starting construction in the park right now.
To learn more, read the official press release: ASU Research Park Celebrates 30 Years – Press Release, or visit the park’s website: asuresearchpark.com.
PADT was honored to be invited to come out and see the Formula SAE car that Arizona State University has been working on as part of their Press Day at the Bondurant School of High Performance Driving. The PADT Hat came along and got a picture:
We helped out the team last year by printing them an intake manifold and by offering some assistance to the Aero design team. It was a very nice design and in their first year of competition, they came in 24th out of 80 teams.
Congratulations to all the students involved and we are looking forward to working with them in the coming season.