Computational design synthesis of additive manufactured multi-flow nozzles

Abstract Additive manufacturing (AM) enables highly complex-shaped and functionally optimized parts. To leverage this potential the creation of part designs is necessary. However, as today’s computer-aided design (CAD) tools are still based on low-level, geometric primitives, the modeling of complex geometries requires many repetitive, manual steps. As a consequence, the need for an automated design approach is emphasized and regarded as a key enabler to quickly create different concepts, allow iterative design changes, and customize parts at reduced effort. Topology optimization exists as a computational design approach but usually demands a manual interpretation and redesign of a CAD model and may not be applicable to problems such as the design of parts with multiple integrated flows. This work presents a computational design synthesis framework to automate the design of complex-shaped multi-flow nozzles. The framework provides AM users a toolbox with design elements, which are used as building blocks to generate finished 3D part geometries. The elements are organized in a hierarchical architecture and implemented using object-oriented programming. As the layout of the elements is defined with a visual interface, the process is accessible to non-experts. As a proof of concept, the framework is applied to successfully generate a variety of customized AM nozzles that are tested using co-extrusion of clay. Finally, the work discusses the framework’s benefits and limitations, the impact on product development and novel AM applications, and the transferability to other domains.