JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - 35

used to generate physical parts for visualization purposes. Finished parts were
only required to keep their mechanical
integrity for handling and demonstration purposes. The focus was not
on designing materials tailor-made
for a specific purpose nor fine-tuning
process parameters, and deposition
strategies to reach the best dimensional
accuracy and part performance. This
lack of process control extends to the
qualification process. The production
quality of a part will rely on the operator's skills and experience to constantly
adjust process parameters. If cost- and
time-consuming trial-and-error attempts could be avoided by providing
reliable sensitivity quantification on
process parameters to secure consistent
printing conditions, AM would become a robust manufacturing method.

Simulation tools
e-Xstream engineering is developing
simulation tools within the Digimat
software suite for SLS and FDM process modelling (figure 1). These tools
enable engineers to design 3D printed
parts that meet all the dimensional and
structural requirements while accounting for the chosen printing technology
specificities. The proposed approach
to additive manufacturing modelling
is built along three deeply connected
aspects:
- Material engineering: design new

materials whose microstructure and
physical properties are consistent.
Both with the requirements of a specific AM technology and the targeted
final application.
- Process simulation: optimize printing parameters to improve dimensional accuracy, surface finish and
reduce manufacturing time while predicting residual stresses and strains.
- Evaluate and optimize the performance of 3D printed parts: simulate
the mechanical response of as-manufactured parts to improve part
shape and manufacturing orientation
including real printed dimensions,
process-induced defects and local
material properties.

Polimotor project
The presented workflow was successfully applied to the Polimotor plenum
from the Polimotor 2 project, whose
principal material sponsor is Solvay,
a global leader in advanced polymer
solutions (figure 2). The Polimotor
project aims to open the way for a
technological breakthrough in the
automotive sector by replacing up to
ten metal parts by plastic materials in
the Polimotor 2 engine. The studied
plenum is produced through selective laser sintering using a Sinterline®
Technyl® polyamide 6 (PA6) powder
grade reinforced with a 40% loading of
glass beads.

Confirming the design
A multiscale thermomechanical material-reinforced plastic was created with
Digimat, and subsequently used for
both process and structural engineering. The layer-by-layer manufacturing
of the plenum was modelled, followed
by a static calculation to establish the
ultimate pressure loading the part
could withstand while operating. A low
distortion from the targeted shape was
predicted, as well as a maximum sustained pressure of 9.1 bars, which confirmed the plenum design. In addition,
manufacturing guidance was provided
by optimizing the printing direction
such that the ultimate sustainable load
could be increased by 40% without
adjusting the geometry.

Process control
Integrated structural and material
design tools are needed to accelerate
the adoption of AM by the aerospace
and automotive design community and
to promote new innovative structural
designs needed to save energy and
weight. Experimental feedback is not
enough to build a reliable production
workflow. Process control is the key
to reach the desired dimensional and
structural requirements of 3D printed
part design. n
More information:
www.e-xstream.com

No105 June 2016 / jec

Feature Simulation

Fig. 2: (a) Polimotor 2 plenum printed with Sinterline®; (b) distortion - distance to targeted part (mm); (c) failure indicator distribution yellow color indicates critical
failure spots

composites magazine 35


http://www.e-xstream.com

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #105 - June 2016

Cover
Edito
Point of view: eastern promises
Contents
COMPANY & BUSINESS
APPLICATIONS
Quickstep contract to open up South Korean automotive market
Development
Design methods
Agenda of Events
APPLICATIONS
Aeronautics
Kayak
Robot
MARKET
Software
Brazil
FEATURE SIMULATION
Flow simulation
Microstructure
Damage
3D-printing
Data
Data
RESEARCH & DEVELOPMENT
Smart composites
Laser cutting
TECHNOLOGY & INNOVATIONS
Testing
Efficiency
Index
In the world
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - Cover
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - 2
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - Edito
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - Point of view: eastern promises
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - 5
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - Contents
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - 7
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - Quickstep contract to open up South Korean automotive market
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - 9
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - Development
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - 11
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - Design methods
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - 13
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - Agenda of Events
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - 15
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - Ad1
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - Ad2
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - Aeronautics
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - Kayak
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - Robot
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - Software
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - 20
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - 21
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - 22
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - 23
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - Brazil
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - 25
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - Flow simulation
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - 27
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - 28
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - Microstructure
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - 30
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - Damage
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - 32
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - 33
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - 3D-printing
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - 35
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - Data
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - 37
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - Data
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - 39
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - 40
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - 41
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - Smart composites
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - 43
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - 44
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - 45
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - Laser cutting
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - 47
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - 48
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - 49
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - 50
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - Testing
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - 52
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - 53
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - 54
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - Efficiency
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - 56
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - Index
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - In the world
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - 59
JEC COMPOSITES MAGAZINE - Issue #105 - June 2016 - 60
https://www.nxtbook.fr/newpress/jeccomposites/jcm1911_Special_Issue2
https://www.nxtbook.fr/newpress/jeccomposites/jcm1911_131
https://www.nxtbook.fr/newpress/jeccomposites/jcm1909_130
https://www.nxtbook.fr/newpress/jeccomposites/jcm1907_129
https://www.nxtbook.fr/newpress/jeccomposites/jcm1905_128
https://www.nxtbook.fr/newpress/jeccomposites/jcm1903_Special_Issue1
https://www.nxtbook.fr/newpress/jeccomposites/jcm1903_127
https://www.nxtbook.fr/newpress/jeccomposites/jcm1901_126
https://www.nxtbook.fr/newpress/jeccomposites/jcm1811_125
https://www.nxtbook.fr/newpress/jeccomposites/jcm1810_124
https://www.nxtbook.fr/newpress/jeccomposites/jcm1808_123
https://www.nxtbook.fr/newpress/jeccomposites/jcm1807_122
https://www.nxtbook.fr/newpress/jeccomposites/jcm1805_121
https://www.nxtbook.fr/newpress/jeccomposites/jcm1804_120
https://www.nxtbook.fr/newpress/jeccomposites/jcm1803_119
https://www.nxtbook.fr/newpress/jeccomposites/jcm1802_119-Supplement_Innovation_Report
https://www.nxtbook.fr/newpress/jeccomposites/jcm1801_118
https://www.nxtbook.fr/newpress/jeccomposites/jcm1711_117
https://www.nxtbook.fr/newpress/jeccomposites/jcm1710_116
https://www.nxtbook.fr/newpress/jeccomposites/jcm1708_115
https://www.nxtbook.fr/newpress/jeccomposites/jcm1707_114
https://www.nxtbook.fr/newpress/jeccomposites/jcm1706_113
https://www.nxtbook.fr/newpress/jeccomposites/jcm1704_112
https://www.nxtbook.fr/newpress/jeccomposites/jcm1703_111
https://www.nxtbook.fr/newpress/jeccomposites/jcm1701_110
https://www.nxtbook.fr/newpress/jeccomposites/jcm1611_109
https://www.nxtbook.fr/newpress/jeccomposites/jcm1610_108
https://www.nxtbook.fr/newpress/jeccomposites/jcm1608_107
https://www.nxtbook.fr/newpress/jeccomposites/jcm1607_106
https://www.nxtbook.fr/newpress/jeccomposites/jcm1605_105
https://www.nxtbook.fr/newpress/jeccomposites/jcm1604_104
https://www.nxtbook.fr/newpress/jeccomposites/jcm1603_103
https://www.nxtbook.fr/newpress/jeccomposites/jcm1601_102
https://www.nxtbook.fr/newpress/jeccomposites/jcm1511_101
https://www.nxtbook.fr/newpress/jeccomposites/jcm1510_100
https://www.nxtbook.fr/newpress/jeccomposites/jcm1509_99
https://www.nxtbook.fr/newpress/jeccomposites/jcm1507_98
https://www.nxtbook.fr/newpress/jeccomposites/jcm1505_97
https://www.nxtbook.fr/newpress/jeccomposites/jcm1504_96
http://www.nxtbook.com/newpress/jeccomposites/jcm1503_95
http://www.nxtbook.com/newpress/jeccomposites/jcm1501_94
http://www.nxtbook.com/newpress/jeccomposites/jcm1412_93
http://www.nxtbook.com/newpress/jeccomposites/jcm1410_92
http://www.nxtbook.com/newpress/jeccomposites/jcm1409_91
http://www.nxtbook.com/newpress/jeccomposites/jcm1406_90
http://www.nxtbook.com/newpress/jeccomposites/jcm1405_89
http://www.nxtbook.com/newpress/jeccomposites/jcm1404_88
http://www.nxtbook.com/newpress/jeccomposites/jcm1403_87
http://www.nxtbook.com/newpress/jeccomposites/jcm1401_86
http://www.nxtbook.com/newpress/jeccomposites/jcm1311_85
http://www.nxtbook.com/newpress/jeccomposites/jcm1310_84
http://www.nxtbook.com/newpress/jeccomposites/jcm1308_83
http://www.nxtbook.com/newpress/jeccomposites/jcm1307_82
http://www.nxtbook.com/newpress/jeccomposites/jcm1305_81
http://www.nxtbook.com/newpress/jeccomposites/jcm1304_80
http://www.nxtbook.com/newpress/jeccomposites/jcm1303_79
http://www.nxtbook.com/newpress/jeccomposites/jcm1301_78
http://www.nxtbook.com/newpress/jeccomposites/jcm1212_77
http://www.nxtbook.com/newpress/jeccomposites/jcm1210_76
http://www.nxtbook.com/newpress/jeccomposites/jcm1208_75
http://www.nxtbook.com/newpress/jeccomposites/jcm1207_74
http://www.nxtbook.com/newpress/jeccomposites/jcm1206_73
http://www.nxtbook.com/newpress/jeccomposites/jcm1204_72
http://www.nxtbook.com/newpress/jeccomposites/jcm1203_71
http://www.nxtbook.com/newpress/jeccomposites/jcm1201_70
http://www.nxtbook.com/newpress/jeccomposites/jcm1111_69
http://www.nxtbook.com/newpress/jeccomposites/jcm1110_68
http://www.nxtbook.com/newpress/jeccomposites/jcm1108_67
http://www.nxtbook.com/newpress/jeccomposites/jcm1107_66
http://www.nxtbook.com/newpress/jeccomposites/jcm1105_65
http://www.nxtbook.com/newpress/jeccomposites/jcm1104_64
http://www.nxtbook.com/newpress/jeccomposites/jcm1103_63
http://www.nxtbook.com/newpress/jeccomposites/jcm1101_62
http://www.nxtbook.com/newpress/jeccomposites/jcm1011_61
http://www.nxtbook.com/newpress/jeccomposites/jcm1010_60
http://www.nxtbook.com/newpress/jeccomposites/jcm1009_59
http://www.nxtbook.com/newpress/jeccomposites/jcm1006_58
http://www.nxtbook.com/newpress/jeccomposites/jcm1005_57
http://www.nxtbook.com/newpress/jeccomposites/jcm1004_56
http://www.nxtbook.com/newpress/jeccomposites/jcm1003_55
http://www.nxtbook.com/newpress/jeccomposites/jcm1001_54
http://www.nxtbook.com/newpress/jeccomposites/jcm0911_53
http://www.nxtbook.com/newpress/jeccomposites/jcm0910_52
http://www.nxtbook.com/newpress/jeccomposites/jcm0909_51
http://www.nxtbook.com/newpress/jeccomposites/jcm0907-08_50
http://www.nxtbook.com/newpress/jeccomposites/jcm0906_49
http://www.nxtbook.com/newpress/jeccomposites/jcm0904_48
http://www.nxtbook.com/newpress/jeccomposites/jcm0903_47
http://www.nxtbook.com/newpress/jeccomposites/jcm0901_46
http://www.nxtbook.com/newpress/jeccomposites/jcm0811_45
http://www.nxtbook.com/newpress/jeccomposites/jcm0810_44
http://www.nxtbook.com/newpress/jeccomposites/jcm0809_43
http://www.nxtbook.com/newpress/jeccomposites/jcm0807_42
http://www.nxtbook.com/newpress/jeccomposites/jcm0806_41
http://www.nxtbook.com/newpress/jeccomposites/jcm0805_40
http://www.nxtbook.com/newpress/jeccomposites/jcm0803_39
http://www.nxtbook.com/newpress/jeccomposites/jcm0801_38
http://www.nxtbook.com/newpress/jeccomposites/jcm0712_37
http://www.nxtbook.com/newpress/jeccomposites/jcm0710_36
http://www.nxtbook.com/newpress/jeccomposites/jcm0709_35
http://www.nxtbook.com/newpress/jeccomposites/jcm0707_34
http://www.nxtbook.com/newpress/jeccomposites/jcm0706_33
http://www.nxtbookMEDIA.com