Optimal Design Exploiting 3D Printing and Metamaterials (Manufacturing)

Cover
Contents
About the editors
Introduction
1 Innovative materials, computational methods and their disruptive effects
	1.1 Materials that changed the world
		1.1.1 Ancient disruptive materials
			1.1.1.1 Ceramic
			1.1.1.2 Brick
			1.1.1.3 Metals
			1.1.1.4 Gold and silver: early uses
			1.1.1.5 Gold and silver: money
			1.1.1.6 Copper
			1.1.1.7 Bronze
			1.1.1.8 Iron
			1.1.1.9 Concrete
			1.1.1.10 Blown glass
			1.1.1.11 Silk and porcelain
		1.1.2 Materials of the industrial revolution
			1.1.2.1 Cast iron and steam engine
			1.1.2.2 Special steels
			1.1.2.3 Electrolytic copper, communications and power transmission
			1.1.2.4 Electrolytic aluminium and airplanes
			1.1.2.5 Tungsten, ribbon glass and the incandescent lamps
			1.1.2.6 Pure semiconductors and solid-state electronics
			1.1.2.7 Plastics
			1.1.2.8 The emergence of composite materials
	1.2 Computing machines and computers
		1.2.1 Ancient mechanical computing
		1.2.2 Mechanical calculators
		1.2.3 Mechanical and electromechanical computers
		1.2.4 Wartime electronic computers
		1.2.5 Generations of electronic computers
		1.2.6 Supercomputers
		1.2.7 Software
	1.3 Numerical methods
		1.3.1 Numerical methods in antiquity
		1.3.2 Numerical methods in the early modern period
		1.3.3 Numerical methods in the modern period
		1.3.4 Numerical methods in the twentieth century
		1.3.5 Computerized numerical methods
	1.4 Numerical optimization
		1.4.1 Deterministic optimization
		1.4.2 Stochastic optimization
	1.5 Numerical models for continuum models
		1.5.1 FDMs for ODEs and PDEs (1920s)
		1.5.2 FEM for PDEs (1940s)
		1.5.3 Other methods (1960s)
		1.5.4 Key developments in computational electromagnetics
	References
2 Advances and trends in design optimisation
	2.1 The hierarchical design paradigm
	2.2 The ‘no free lunch’ theorem
	2.3 Surrogate modelling
	2.4 The concept of a robust design
	2.5 The advances in computational electromagnetics
	2.6 Computer-aided design
	2.7 Singleand multi-objective optimisation
	2.8 Pareto optimisation
	2.9 Balancing exploitation and exploration
	2.10 Kriging techniques
	2.11 Numerical experiments using test functions
	2.12 An engineering example
	2.13 A brief review of nature inspired algorithms
	2.14 The challenge of large data sets
	2.15 Points aggregation techniques
	2.16 Design sensitivity aspect
	2.17 Future trends
		2.17.1 Model order reduction
		2.17.2 Deep learning
		2.17.3 Cloud computing
		2.17.4 Multi-physics
	2.18 Benchmarking
	2.19 Concluding remarks
	References
3 Free-form optimal design in electromagnetism exploiting 3D printing
	3.1 Introduction
	3.2 Inverse problems and optimal shape design
	3.3 State of the art
	3.4 A comparative view of methods
	3.5 Free-form optimisation
	3.6 A simple algorithm for dielectric design
		3.6.1 Dielectric design oriented free-form optimisation
		3.6.2 Optimisation results
	3.7 A posteriori overview of optimal shape design
	3.8 An enabling technology: towards Industry 4.0, level by level
	3.9 An overview of technologies
		3.9.1 A technology that could have in the near future a single limit: imagination
		3.9.2 Fused deposition modelling
		3.9.3 Stereolithography and digital light processing
		3.9.4 Selective laser sintering
		3.9.5 Multi-jet fusion
		3.9.6 Material jetting printing
		3.9.7 Electron beam melting
		3.9.8 Binder jetting
		3.9.9 3D multi-material printing
	3.10 Materials vs meta-materials
	3.11 3D printing: a practical implementation
	3.12 Recent FDM experiences in electromagnetism
	3.13 Pros and cons of the new approach
	3.14 3D printing oriented optimal design
	3.15 Driving the slicing: process-oriented coding
	3.16 Technology-related sensitivity
	3.17 Conclusion
	List of acronyms
	References
4 Innovative motors and shape optimisation
	4.1 Trends in electric motor technology
	4.2 What makes an electric motor innovative?
		4.2.1 Novel design topologies
			4.2.1.1 Innovative stator winding
		4.2.2 Novel materials
			4.2.2.1 Core lamination materials
			4.2.2.2 Soft magnetic composite materials
			4.2.2.3 Permanent magnet materials
		4.2.3 Novel production technologies
			4.2.3.1 Winding production technology
			4.2.3.2 Electric motors from 3D printer
			4.2.3.3 Heat dissipation and cooling
			4.2.3.4 Power supply and control trends
		4.2.4 Concluding remarks
	4.3 Design optimisation of electric motors
		4.3.1 Nature-inspired algorithms
			4.3.1.1 Genetic algorithm
			4.3.1.2 Particle Swarm Optimisation
			4.3.1.3 Cuckoo search algorithm
		4.3.2 Case study
			4.3.2.1 Surface-mounted permanent magnet – SMPM motor
			4.3.2.2 Definition of the objective function
			4.3.2.3 Selection of design variables
			4.3.2.4 Setting optimisation assumptions
		4.3.3 Optimisation results
			4.3.3.1 Genetic algorithm optimisation
			4.3.3.2 Particle swarm optimisation
			4.3.3.3 Cuckoo search optimisation
		4.3.4 Comparative analysis
		4.3.5 Concluding remarks
	4.4 FEA-based shape synthesis of electric motors
		4.4.1 Case study background
		4.4.2 Numerical experiment
		4.4.3 Selection of optimal shape design
			4.4.3.1 Fine-tuning of stator poles’ design
		4.4.4 Analysis of the results
			4.4.4.1 Cogging torque analysis
			4.4.4.2 Static torque analysis
		4.4.5 Concluding remarks
	4.5 Summary
	References
5 Frontiers and challenges of new ferromagnetic materials
	5.1 Ferromagnetic materials
		5.1.1 Soft magnetic materials
		5.1.2 Semi-hard magnetic materials
		5.1.3 Hard magnetic materials
	5.2 Methods of magnetic materials production
	5.3 Application of ferromagnetic materials
	5.4 Frontiers of application of ferromagnetic materials
		5.4.1 Magnetic properties
		5.4.2 Mechanical properties
		5.4.3 Temperature properties
		5.4.4 Shape and dimension limitation
		5.4.5 Price limitations
	5.5 Challenges of new ferromagnetic materials
		5.5.1 Soft magnetic materials
		5.5.2 Hard magnetic materials
	5.6 New technologies of magnetic materials production
	5.7 Conclusion
	References
6 Synthesising metamaterials with 3D printing and conductive layers
	6.1 3D gradient dielectric metamaterials
		6.1.1 3D gradient dielectric metamaterial anatomy
		6.1.2 3D metamaterial synthesis techniques
		6.1.3 Example application – flat Luneburg lens
	6.2 Resonators and resonator arrays
		6.2.1 Introduction
	6.3 Circuit-equivalent models of resonators
	6.4 Distributed circuit-equivalent models of resonators
		6.4.1 Resonator arrays – mutual coupling
	6.5 Full-wave FDTD numerical models of resonators
	6.6 Flat metasurface lens for MRI applications
	6.7 Artificial magnetic conductor
		6.7.1 Reflection phase estimation method
		6.7.2 AMC structure optimisation
	6.8 Frequency-selective metasurfaces in the THz band
	6.9 2D and 3D printing techniques
		6.9.1 3D printing complex internal structures
		6.9.2 Transforming 3D voxel images to G-code directly
	6.10 Conclusion
	References
7 Industrial design perspectives
	7.1 Current and potential trends
		7.1.1 Design of complex geometries for manufacturability
		7.1.2 3D printing in manufacturing metamaterials
		7.1.3 Opportunities and future directions
		7.1.4 Disruptive design perspectives
	7.2 Applicability and adaptability
		7.2.1 Rapid prototype
		7.2.2 Industrial design challenges
			7.2.2.1 Standardisation in the AM sector
			7.2.2.2 Software resources
		7.2.3 Limitations in integration AM with metamaterials
		7.2.4 Topology optimisation and additive manufacturing
	7.3 Research progress and industry application
		7.3.1 Manufacturing and prototyping
		7.3.2 AM integration challenges to scaled production
		7.3.3 Industrial sectors and applications
	7.4 Market segments
		7.4.1 An overview of current size and growth trends
		7.4.2 Online 3D printing and services providers
	7.5 Promising directions and examples
		7.5.1 Successful examples in industry
			7.5.1.1 3D-printed fuel nozzles
			7.5.1.2 3D-printed solar panels
			7.5.1.3 3D-printed windings for electric cars
			7.5.1.4 3D-printed electric drive housing
			7.5.1.5 Largest 3D-printed rocket engine
			7.5.1.6 Largest 3D-printed internal combustion engine
		7.5.2 How AM could innovate future electrical machines
	7.6 Conclusions
	References
Conclusion
In memoriam
Index
Back Cover