Category Archives: Case

• Goal: Redesign a “stator housing” with an improved cooling capacity and the lowest possible pressure drop that is manufactured by means of 3D metal printing.• Approach: van den Kroonenberg design methodology.• Result: reduction of average temperature and pressure drop (original was not measured). The students came up with a completely different concept than theContinue reading “Biz 2 Case 3 – Stator Housing (Aeronamic)”

Stator housing & Proces workflow-analyse (Aeronamic) • Goal: Optimizing a cooling body and mapping the workflow when designing and producing by means of 3D metal printing.• Approach: Van den Kroonenberg design methodology.• Outcome: Study optimal cooling structure and workflow schedule.• Profit for the company: The outcomes of the research into an optimal cooling structure. InsightContinue reading “Biz 2 Case 2 – Stator housing & Proces workflow-analyse (Aeronamic)”

Linear conductor optimisation (AWL) • Goal: Weight optimization, shortening lead time, function integration.• Approach: Iterative design process, 3 iterations.• Result: 46% weight saving, 2 functions integrated.• Profit for the company: This project has given the impetus to thinking differently for 3D metal printing, the company has purchased a 3D metal printer partly because of thisContinue reading “Biz 2 Case 1 – Linear conductor optimisation (AWL)”

Improve impeller efficiency using 3D metal printing (3Dealise) • Goal: To investigate which working method can be used to design and print an optimal impeller• Approach: literature research into impellers, design impeller, simulate and optimize for 3D metal printing, create and print print files, post-processing• Outcome: an impeller design optimized for 3D metal printing, andContinue reading “Biz 1 Case 13 – Improve impeller efficiency using 3D metal printing (3Dealise)”

Optimal heat treatment (Pontus) • Goal: To determine the most suitable temperature and the time required for the heat treatment of the 3D metal printed product. Determining the deformation of the 3D metal printed product according to the design guidelines after the heat treatment.• Approach: print samples, have samples undergo various heat treatments (temperature 450Continue reading “Biz 1 Case 12 – Optimal heat treatment (Pontus)”

Physically printed optimal mold (Protype) • Purpose: To determine how flat and smooth a mold can be printed (without finishing operations).• Approach: redesign mold, print mold, testing• Result: We succeeded in printing an optimized mold with a complex cooling channel and a pillar textile that is only possible with 3D printing. However, the print isContinue reading “Biz 1 Case 11 – Physically printed optimal mold (Protyp)”

Smallest fluid channels (PM Bearings) • Objective: To investigate the smallest possible hole diameter that can be printed in a PECM tool (precision tool with very small fluid channels, Precision Electro Chemical Machining).• Approach: Print multiple samples containing various channels (0.2 mm, 0.3 mm, 0.4 mm) and wall thicknesses, cut samples and examine them microscopically.•Continue reading “Biz 1 Case 10 – Smallest fluid channels (PM Bearings)”

Lattice structures • Goal: To determine which mass reduction can be realized with the most optimal and printable lattice structures.• Approach: designing lattice structures and designing test samples with lattice structures, printing samples, performing destructive mechanical testing with the samples• Outcome: Unfortunately the lattice structures cannot handle the required forces, so it will not beContinue reading “Biz 1 Case 8 – Most optimal lattice structure (Thales)”

Topologische optimalisatie (Thales) • Objective: To investigate when topologically optimized (ie computer generated) designs can offer added value for production using 3D metal printing.• Approach: Research into software for topological optimization, and build up experience with its use.• Outcome: The entire process from design to production must always be viewed critically. The optimized result mustContinue reading “Biz 1 Case 7 – Topologische optimalisatie (Thales)”

Improve distribution block (Aebi Schmidt) Doel: Vaststellen van de vrije ontwerpruimte in het (her)ontwerp van een dunwandig verdeelblok dat klant specifiek ontworpen en geprint moet worden. Aanpak: Volumestromen bepalen, FEM simulaties van flow en sterkte uitvoeren, ontwerpen en optimaliseren, printen, testen Uitkomst: Er is een verdeelblok ontworpen dat geprint kan worden zonder support materiaal meeContinue reading “Biz 1 Case 6 – Improve distribution block (Aebi Schmidt)”