Integrating additive manufacturing (AM) remake strategies using Optimus, early in conceptual design enhances product longevity and sustainability, aligning with global goals for responsible consumption and production. By optimizing designs for repair and remanufacture, industries can reduce waste, conserve resources, and foster a more resilient circular economy, benefiting both the environment and economic sustainability.
The groundwork for modern manufacturing, transportation and energy systems was laid in the Industrial Revolution, putting a focus on maximizing production and profit disregarding the environmental impact. The "Make-Use-Dispose" industrial model that emerged has led to environmental degradation on a massive scale. The construction and manufacturing industries are two of the biggest contributors to waste in the European Union, together accounting for nearly half of the total solid waste generated in 2020.
But there’s a growing awareness and a shift in mindset towards sustainability. The Dutch government, for instance, is aiming to cut down the consumption of primary raw materials by 50% by 2030, with a vision of a fully circular economy by 2050. Circular economy seeks to replace the existing unsustainable industrial model with one that is regenerative and restorative by design, keeping products at their highest utility and value throughout their lifecycle. This is where Optimus, automation and optimization tool by Noesis Solutions, comes into play.
Optimus, an Automation and Optimization tool by Noesis Solutions, enables users to outsmart competition while taking into account all relevant design constraints - effectively implementing an Objectives Driven Engineering process, and saving time & resources. Optimus bundles a powerful range of capabilities for Engineering Process Integration, Design Space Exploration, Engineering Optimization and Robustness & Reliability. Optimus’ advanced numerical optimization algorithms easily resolve even the toughest multi-disciplinary multi-objective optimization challenges.
Optimus’ state-of-the-art, advanced machine learning technologies allow us to emulate real-world scenarios with precision, enabling designers to create products with end-of-life recovery strategies in mind right from the conceptual design phase. We recently worked with Mr. Talal Akkaoui, M.Sc, TU Delft, for a case study with a leading car manufacturer, that aims to implement an additive manufacturing (AM) repair strategy into a component’s conceptual design using Optimus’ multidisciplinary design optimization.
This research integrates a foundational design optimization workflow using Optimus, for additive manufacturing repair that implements a damage analysis into the conceptual design. A car loudspeaker mesh is used as a case study. Throughout the optimization process, Optimus informs engineers on the ongoing progress, allowing them to steer the process based on their extensive experience. Regardless of process’ complexity, Optimus design optimization searches and finds optimal design candidates that outsmart competition. Optimus’ interactive post-processing and visualization tools enables engineers to convert simulation results into clear decision metrics.
Read the entire case study here - https://www.noesissolutions.com/cases/multidisciplinary-design-optimization-for-additive-manufacturing-repair
This paper has potential of being a valuable conceptual design tool that would encourage sustainable strategies in the conceptual design process using Optimus. Even though it will require further developments to provide more reliable performance information to the designer, it highlights the potential of including end-of-life scenarios into the design process at an early stage.
Integrating AM remake strategies early in the conceptual design phase presents an opportunity to:
Imagine a future where products are designed not just for performance and manufacturability but also for how they will be repaired, reused, or remanufactured at the end of their life. This shift in design philosophy could drastically reduce waste and resource consumption. CAE tools, for example, can simulate how a product might fail or be repaired, providing valuable insights that inform more sustainable design choices. Meanwhile, advancements in robotics and digital fabrication are making it possible to perform complex repairs and reverse engineering with greater efficiency and less reliance on skilled labor.
By rethinking how we design, manufacture, and manage the end-of-life of our products, we can take significant strides towards a more sustainable industrial future. Integrating circular economy principles and leveraging multidisciplinary optimization focusing on the same, we can create products that are not only high-performing but also sustainable throughout their entire lifecycle.
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