CDFAM Computational Design Symposium

Recorded at CDFAM Computational Design Symposium, NYC 2024

Presentation Abstract

Sandia National Labs is a systems integrator and design agency with additional production responsibility for critical components. As such, advanced and additive manufacturing offer significant potential value to our mission responsibilities. Novel functionality and efficiencies can be achieved through complex part geometries, design of new or functionally graded composites or nano-structured materials, and the leveraging of data via a “network of things” and machine-learned models for integrated AI controls and process optimization. Taken together, if fully realized, these developments hold out promise for a new era of digitally integrated product realization that is precise, responsive, and “smart”. However, shortcomings in establishing the technical basis for determining reliable performance margins persist due to the complex, coupled physical processes that create the final material as the part itself is being built. Developing sufficient scientific understanding of these processes to achieve the levels of control required for rapid realization and qualification of processes or parts is itself a challenge. A true design for AM methodology must further invert this scientific understanding to achieve targeted performance margins. This presentation details a number of ongoing efforts to develop a physics-based modeling framework for advanced and additive manufacturing that is predictive of process outcomes based on settings and can be used to provide optimized design workflows. Examples are shown for DIW stress pads and cushions and metal laser powder bed fusion.

This work was supported by the LDRD program at SNL, managed and operated by NTESS under DOE NNSA contract DE-NA0003525.

Speaker Bio

Jeremy Lechman is manager of the Energetics, Multiphase and Soft Matter Sciences Department, Engineering Sciences Center, Sandia National Laboratories

CDFAM Computational Design Symposium series brings together leading experts in computational design from industry, academia and software development for two days of knowledge sharing and networking.

Visit CDFAM.COM to learn about upcoming events around the world.

Recorded at CDFAM Computational Design Symposium, NYC 2024

Presentation Abstract

Presentation Abstract

LifEnabled makes custom-fit prosthetic devices for the developing world that are simple, durable and new. Partner with LifEnabled to impact the world.

Speaker Bio

Brent Wright, CP, BOCO,  is a Partner and Designer at Advanced 3D, and a clinician for patients on the ground at Eastpoint Prosthetics and Orthotics in Raleigh, NC.  While he has a background with Fused Deposition Modeling (FDM), Brent has been utilizing new methods using MultiJet Fusion and Selective Laser Sintering lately, looking to create prostheses that are not only functional but light and flexible.

CDFAM Computational Design Symposium series brings together leading experts in computational design from industry, academia and software development for two days of knowledge sharing and networking.

Visit CDFAM.COM to learn about upcoming events around the world.

Recorded at CDFAM Computational Design Symposium, NYC 2024

Presentation Abstract

For the additive manufacturing industry to grow, unlocking production applications is critical. Building web applications targeting the AM industry is needed to make 3D printing easier to use in production settings. However, developing cloud-based applications that deal with complex geometries and CAD-like capabilities typically requires specialized expertise and a lengthy development process.

This talk describes how two AM startups worked together to bring a web application for additive manufacturing to market in a compressed timeframe. We will present General Lattice’s Frontier web application for digital materials and describe their use of the Metafold implicit geometry kernel API.

This collaboration allowed General Lattice to focus on their differentiated IP: offering validated materials and geometries from partner vendors to facilitate expedited path to commercialization.

Speaker Bios

Daniel is an entrepreneur and mathematician with extensive experience in geometric computing for the Additive Manufacturing industry. Before co-founding Metafold, Daniel held numerous roles in engineering firms working on complex geometric challenges in large-scale commercial construction. He is passionate about solving problems arising in industry with geometry and computation.

Marek Moffett, co-founder General Lattice, leading General Lattice’s computational design and additive manufacturing team, focusing on the generation of lattice architectures and DFAM techniques. 

Leveraging years of research across several aspects of latticing, my goal is to deliver advanced material solutions to the industry, ultimately driving a wide spread adoption of superior performing products.

CDFAM Computational Design Symposium series brings together leading experts in computational design from industry, academia and software development for two days of knowledge sharing and networking.

Visit CDFAM.COM to learn about upcoming events around the world.

Recorded at CDFAM Computational Design Symposium, NYC 2024

Presentation Abstract

KPF’s computational geometry processes, whether generating complex building components, documenting, optimizing, rationalizing, or form-finding, consistently rely on a set of core common methods.

Across geometrically and computationally diverse projects, we have identified a repeated pattern and codified 5 distinct methods that form the logical underpinning of almost every bespoke computational task. These methods—data branching, point sorting, plane-based calculation, cross-referencing, and surface rebuilding—form the foundation of our architectural geometric computation process, much like the unseen bulk of an iceberg beneath the water’s surface.

The majority of the work in each computational project involves a combination of these five methods; only after establishing these foundational logics can we implement the bespoke computational logic that handles the specific geometric tasks.

Despite their apparent simplicity, these core functions can become extraordinarily complex in large projects due to the vast number of conditions and edge cases which require our core methods to be standardize and scalable. As project complexity increases, these elemental functions become much more important than bespoke computational logics to ensure that all geometric conditions are accounted for. In this presentation, we will define the main foundational methods of computational geometry and then use several geometrically and logically diverse megaprojects to illustrate how these foundational methods form the majority of the computational logic in each.

Through classification and case studies, we will codify the core geometric computational methods required to develop any large architectural project at scale

Speaker Bio

Madeleine Metawati Eggers is a computational design specialist at KPF who specializes in parametric modeling and computational problem solving on large-scale and complex buildings. As a core member of the KPF computational design team, she has worked with leadership to guide the computational design team’s role in the office as collaborators in the design process, particularly in representing qualitative design problems such that they can be solved computationally.

CDFAM Computational Design Symposium series brings together leading experts in computational design from industry, academia and software development for two days of knowledge sharing and networking.

Visit CDFAM.COM to learn about upcoming events around the world.

Recorded at CDFAM Computational Design Symposium, NYC 2024

Presentation Abstract

Prosthetic sockets for people with amputation are traditionally provided using a manual, plaster-based process where the clinician captures the shape of the limb using a plaster cast, makes modifications to this surface to load and off-load particular biomechanical regions, before this modified shape is used as the base to fabricate the final device.  

While digital processes have been around for several decades, which use 3D scanning and surface-based sculpting tools to replicate the traditional processes, using this digital record to learn from and support the socket design processes has been limited. With increasing adoption of 3D printing in the industry, the need for data to support in device design and fitting is increasing. 

Radii Devices are a UK-based startup using machine learning techniques to learn from historical records and support fitting of these devices within a clinical setting. By providing clinicians access to this technology at the point-of-care, their aim is to provide an improved fitting process for both clinicians and prosthetic users. 

Speaker Bios

Nathan Shirley, Lead Computational & Industrial Designer, HP Computational Design

Nathan helps lead a tactical Design, Engineering, UX and SW team that implements mass customization design engines for HP’s 3D printing customers. We operate as a highly specialized consultancy to help them navigate the complex design and integration path to customizable production at scale in Multi-Jet Fusion, HP’s industrial 3D printing Technology. We focus mainly on Medical & Consumer Body Fitment use cases like orthotics, prosthetics, eyewear, footwear and performance sporting gear, as well as on engineered lattice meta-material behaviors.

Joshua Steer, PhD is the Founder and CEO of Radii Devices Ltd.

He completed his PhD in the Bioengineering department of the University of Southampton, UK in 2019, where he continues as a Visiting Research Follow. His prior academic research and subsequent work at Radii focuses on using software and data, such as 3D scans, to support the fitting of Prosthetics and Orthotics, and has contributed to 17 peer-reviewed journal articles. He collaborates on projects with multiple partners including the Department of Veteran Affairs Office of Advanced Manufacturing and National Health Service in the UK.

Full Presentation on Youtube

CDFAM Computational Design Symposium brings together leading experts in computational design from industry, academia and software development for two days of knowledge sharing and networking.

This keynote presentation at CDFAM Computational Design Symposium in NYC, 2024, introduces the innovative ‘Text-to-Spaceship’ concept by Ryan McClelland at NASA Goddard, focusing on the pivotal role of AI in transforming text-based science objectives into mission designs. We discuss how leveraging current and near-term AI technologies can accelerate the entire mission development process, from initial concept through to hardware realization.

Specific attention is given to AI-driven computational design of systems, illustrating how these technologies can improve design agility and performance. By deploying AI to accelerate the translation of scientific goals into tangible mission outputs, we aim to revolutionize spacecraft design and development, unlocking new capabilities and propelling the aerospace industry into a new era of technical innovation and expanded mission capacities.

CDFAM Computational Design Symposium series brings together leading experts in computational design from industry, academia and software development for two days of knowledge sharing and networking.

Visit CDFAM.COM to learn about upcoming events around the world.

Presentation Title: Scaling & Standardizing Patient-Specific Design

This recording of the presentation at the CDFAM Computational Design (+DfAM) Symposium, held in New York City in 2023. The speaker is Adam Wentworth, a notable figure in the healthcare and additive manufacturing field, associated with the Mayo Clinic.

Abstract: Adam Wentworth, a key contributor to the advancements in patient-specific design at the Mayo Clinic, provides an insightful presentation that explores the challenges and solutions associated with scaling and standardizing patient-specific design in healthcare. In his presentation, Wentworth discusses the criticality of personalized healthcare solutions and the role of computational design and additive manufacturing in delivering highly specific and effective treatment options. Drawing from his extensive experience at the Mayo Clinic, Wentworth presents case studies that exemplify the transformative potential of these technologies in healthcare. He explores both the technical and practical aspects of standardizing patient-specific design, offering insights into regulatory considerations, manufacturing processes, and the impact on patient outcomes.

Audience: This presentation is designed for professionals, researchers, and academics in the fields of computational design, additive manufacturing, and healthcare, particularly those with an interest in patient-specific design and personalized healthcare. Individuals seeking a deep understanding of the intersection between healthcare and advanced manufacturing technologies will find this presentation extremely valuable.

Please note: The CDFAM Symposium serves as a renowned platform for the exchange of knowledge among experts in computational design and additive manufacturing. This recording is intended for educational and professional development purposes.

In this CDFAM presentation, Alex Roschli, research staff member at Oak Ridge National Laboratory (ORNL) Manufacturing Demonstration Facility (MDF), discusses his background in robotics, the progression of his research, and the various aspects of his work on advanced toolpath generation for large scale additive manufacturing (AM).

Alex shares his insights on the challenges of materials and processes in additive manufacturing, as well as the potential applications and technology transfer of this process.

Read the full interview with Alex.

Innovative design requires innovative tools to help engineer advanced solutions. André A.R. Wilmes, CEO of Rafinex describes their novel optimization approach with the Möbius Design Workflow at the CDFAM Computational Design (+DfAM) Symposium in NYC, June 14-15 2023.

Recorded live at CDFAM June 14-15 2023, NYC.