HOW ABOUT 

LOSING 

30% WEIGHT 

IN DAY?

THE NEXT LEVEL OF 
LIGHTWEIGHT ENGINEERING

CASTING

FORGING

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MILLING

STAMPING

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3D-PRINTING

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We Are

MOVERS & SHAKERS

ABOUT

Lightweight construction is usually associated with additional costs. This is due on the one hand to expensive materials that are to be used and on the other hand to the higher effort to realize the complex optimized designs.

We are a team of experienced engineers from the fields of automotive, motorsport and aerospace with simulation, optimization and cad background. Our focus is on making lightweight construction affordable and accessible for everyone. We have made it our mission to save your money with lightweight design . We develop the lightest possible components in the manufacturing process you require in an unbeatable time.

 
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CHALLENGE

It is widely acknowledged that relying on topology optimization can lead to lightweight components. Until now a consistent application of structural optimization has been restricted due to the complexity of the topology results and the costly and time consuming process to realize these results in CAD.

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Lightweight potential of designs provided by topology optimization usually gets lost during CAD design process.

 
 

SOLUTION

In order to keep the full  lightweight potential of topology optimization outputs it is mandatory to generate CAD components which are fully based on them. Bionic Mesh Design is providing CAD designs which respect the constraints of the desired manufacturing method while maintaining the shape of the topology result. This is possible through application of subdivision modelling techniques in 3D modelling tools like ZBrush, Blender, Maya etc. where the topology output is transformed to a manufacturable CAD file.

TOPOLOGY OUTPUT

RETOPOLOGY

CAD INTEGRATION

FAST DESIGN ADJUSTMENT

Although the topology optimization provides ideal structures, manual design adjustments may be necessary due to package changes or a relocation of screwing points.
In contrast to the conventional approach in CAD, the component is not redesigned, but can be adapted to the new boundary conditions in minutes.

 

SHAPE OPTIMIZATION

Topology optimizations deliver only a rough idea of the relevant loadpaths according to the loadcases used. There is no information about the dimensions of the loadpaths available. Therefore it is mandatory to have quickly CAD models based on the topology results available that allow for simulations with standard loadcases to evaluate e.g. stress distributions. Often the first results still show hot spots with stress concentrations. Shape optimization can easily reduce these stresses while maintaining the mass of the component. Afterwards our workflow guarantees a fast carry over of the optimized shape to the CAD model.  

MASS

STRESS

FREESHAPE OPTIMIZATION

 

FORGED WISHBONE

TOPOLOGY OPTIMIZATION

RETOPOLOGY

BENEFITS

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Experience has shown a possible design time reduction of 50 to 90 percent compared 

to remodeling topology results in standard

CAD. Due to a fast subdivision modeling process  design modifications  because of package changes can be done in real time.

Investigations of different manufacturing methods can be carried out with final CAD models.   

TIME

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Mass saving no longer coincides with higher manufacturing cost. Keeping the same standard manufacturing method along with less material consumption leads to drastic reduction of part cost.

COST

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PERFORMANCE

In general optimization leads to light, strong and stiff parts. But in addition to that Bionic Mesh Design enables a full carry over of designs generated with  methods like shape optimization to manufacturable CAD models to achieve for example a desired  NVH or ride and handling characteristics of suspension components .

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SUSTAINABILITY

Reduction of the carbon footprint by protecting resources and using them with respect.

 

SERVICES

STRUCTURAL OPTIMIZATION

Based on our many years of experience in simulating and optimizing  structural components we are capabable to define optimization setups for all types of structural components. Optimization can be carried out on single components or on full assemblies.

  • Definition of design spaces according to the available package spaces

  • Topology optimizations with linearized loadcases to find initial loadpath distribution

  • Shape and Free-Shape optimizations with standard loadcases to achieve the optimal structural performance and mass

RETOPOLOGY

  • Application of polygon modelling tools to transfer topology results to manufacturable CAD models

  • Consideration of all manufacturing relevant constraints like draft angles, thicknesses, overhangs, ...

  • Generation of subdivision bodies to be used as solid bodies in CAD tools.

CAD INTEGRATION

Retopolgy output will be imported in CAD by all known CAD interfaces like IGES, STEP, etc. In addition most major CAD tools have their own subdivision modelling environments

  • CATIA (Imagine & shape)

  • Siemens NX (Realize shape)

  • Solid Works (ShapeX, Power Surfacing)

  • Creo Freeform

 

which allow for a direct integration of subdivision bodies.

Subdivision bodies are then handled as standard solid bodies and can be finalized by integrating holes, boolean operations, etc.

STRUCTURAL ANALYSIS

VALIDATION

Finite Element simulations of both the basic models to generate target values and the optimized geometries to validate them are carried out. The common solvers for strength-, stiffness-, NHV- and crash-simulations are used here.

TRAINING

We show you how to get the maximum lightweight potential out of your components in no time. We offer training for the adaptation of Bionic Mesh Design in your company.

  • Software training  (structural optimization, polygon modelling for engineering)

  • Manufacturing constraints

  • CAD integration of  subdivision bodies