What is generative design?
- Generative design is an engineering approach to problem solving with parallels to how species evolve in the natural world. Cloud computing checks each possible design iteration for compliance with constraints defined by the user. This process results in one or more optimal designs to choose from that a human would not have been able to create themselves with a traditional design approach [1].
What is reality computing?
Reality computing is the combination of reality capture and computer aided simulation, ultimately yielding faster designs and solutions. Reality computing captures a 3D image of an object and creates a CAD file from the data. It is much faster than physically taking measurements to create a prototype by hand, and is much more accurate [2].
What are the different types of generative design?
- Form Synthesis- This considers the user-defined constraints to produce an diverse assortment of design options. The user then selects which best aligns with their project goals.
- Lattice and Surface Optimization- Instead of synthesizes possible designs for a model, this form of generative design starts with a user-provided component. An array of internal lattice structures are applied to the component to generate a version with the highest strength to weight ratio possible.
- Topology Optimization- Similar to lattice and surface optimization, this form of generative design imposes changes on an existing component to minimize weight. However, instead of applying intricate lattices to the internal structure, topology optimization analyzes the application of a load across the component to determine where material can be removed while still abiding by design requirements.
- Trabecular Structures- This generative design approach is used in medical applications. It deals with applying networks of pores to the structure of solid materials in a way that mimics human bones [1].
What can be created with generative design?
- With advanced manufacturing techniques, generative design can help create a revolutionary wave of efficient products spanning a wide array of disciplines. Autodesk showcases some industry applications of generative design on its website, such as a hot rod, an airplane, and an athletic sneaker.
What is advanced manufacturing?
- According to the Science and Technology Institute (STPI), a brief definition for advanced manufacturing is "manufacturing that entails rapid transfer of science and technology into manufacturing processes and products" [2]. The recent advancements of 3D printing technology are aspects of advanced manufacturing that can be used with generative design to create innovate products.
What software was used? How?
- The software used in this project all came from the line of Autodesk products. For this project the team used ReMake, Fusion 360, and Netfabb. ReMake was used for the reality computing. Photos taken on a smartphone were uploaded to the Autodesk cloud and processed into a three-dimensional surface mesh in ReMake. The sculpt environment in Fusion 360 was used to superimpose a surface mesh around a model of a leg. This mesh was converted into three-dimensional object with a thickness in the modeling environment to create a usable virtual model of a cast. Netfabb was used to apply lattice structures from predefined shape libraries to this cast model. The resulting models, as well as the original solid-walled model, were tested for their load-bearing capacity in the simulation environment of Fusion 360. With the exception of Autodesk Netfabb, all of the software used is provided to students for free by Autodesk under an education license. The Netfabb features the team needed for this project are only available to holders of enterprise licenses. This software was provided by the TAMG lab at Drexel University.
What is this cast going to be used for?
- The short-leg cast the team is designing can be used to heal fractures of the tibia and fibula and ankle fractures. The function of the cast is to immobilize the broken area while the injury heals post break or surgery.
- What was the most difficult part of the project?
The task that the team found surprisingly difficult was identifying the medical standards of a short-leg cast. Extensive literature was done to identify medical standards such as the compression rate, material used, and the overall structure components. It was important to follow these standards to ensure that the device is viable in an already well-established in the medical field.
[1] Autodesk. What is Generative Design. [Online]. Available: https://www.autodesk.com/solutions/generative-design
[2] Autodesk, “Reality Computing,” In The Fold, 2016. [Online]. Available: http://inthefold.autodesk.com/in_the_fold/reality-computing/. [Accessed: 02-Jun-2017].
[3] Science and Technology Institute (STPI). White Papers on Advanced Manufacturing Questions. [Online]. Available: https://www.nist.gov/sites/default/files/documents/2017/05/09/advanced-manuf-papers.pdf