Authors:

Mariana Peres Duarte

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About Paper:

Additive manufacturing (AM) has enabled the fabrication of parts with complex geometries, unlocking the potential of advanced design methods, such as topology optimization and compliant structures. Residual stresses due to AM have been traditionally perceived as undesirable and cause unpredictable component deformation, particularly in metal-based AM. Additionally, there are limited studies and methods to predict the influence on the response of additive manufactured fabricated thin-walled parts. Residual stresses can be beneficial in the design of compliant structures with multiple stables states, known as multistable structures. In particular, the compliant capabilities of such structures are enhanced in the presence of residual stresses by storing strain energy for shape reconfiguration, allowing for another route towards achieving multistability in structures. By further developing our knowledge surrounding the fabrication process and the resulting structural response of bistable dome-shapes structures, we can familiarize ourselves with the mechanics of the dome shaped-units and predict the resulting mechanical response of thin-walled structures. In this work, we aim to establish a simulation procedure for determining the effect of 3D printing on the mechanical response of thin-walled structures. Specifically, we conduct comprehensive numerical analysis of the selective laser sintering (SLS) and physical testing of a bistable dome using commercial software Abaqus Finite Element Analysis. Model parameters from previous literature were compiled and tested in the simulation to assess its validity, yielding results consistent with those reported in the literature. The results of this study hope to provide a foundation for future additive manufactured modelling of dome-shaped structures. Keywords: Additive Manufacturing; Bistable Structures; Residual Stresses; Simulation

Source:

Purdue University / 2025

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Co-authors:

Mariana Peres Duarte