Title| Multiscale Design of Components and Materials and their Realization via Additive Manufacturing

Speaker| Martin L. Dunn, Dean and Professor of College of Engineering

Time| 1400 – 1500

Venue| Think Tank 22, Building 2, Level 3 (2.311)



In this talk I describe a multiscale digital design and manufacturing workflow that simultaneously determines the macroscopic topology and the spatially-variable microstructure of 3D composite components based on a combination of mathematical homogenization, finite element simulation, and multiscale topology optimization.  Our approach results in a 3D map of homogenized (anisotropic) composite stiffness, parameterized by microstructure descriptors that depend on the specific additive manufacturing technology used to realize the component.  We demonstrate the complete approach with examples from a voxel-based multimaterial photopolymer jetting additive manufacture technology.  Our approach consists of an appropriate representation of the microstructure that is integrated into a multiscale topology optimization framework that simultaneously determines the macroscopic component topology and the microstructural compositional distribution in 3D.  The results of our design automation approach serve as input into an algorithm that creates geometric realizations of optimal designs via an inverse homogenization and generative computational geometry approach and then translates the geometrical realizations into 3D printed components.  We demonstrate our approach by designing 2D, 3D, and multilayer plate composite components, realizing them by 3D printing, and experimentally validating their performance.  We also demonstrate the approach in the context of 4D printing, where components are designed to transform from an as-printed configuration to a new 3D configuration upon heating.

Acknowledgements: Narasimha Bodetti, Oliver Weeger, Zhen Ding, Sawako Kaijima, Markus Geiss, Kurt Maute, H. Jerry Qi.



Martin L. Dunn is a Professor and Dean of the College of Engineering and Applied Science at the University of Colorado Denver.   He joined CU Denver in 2018 after serving as the Associate Provost for Research at the Singapore University of Technology and Design (SUTD).  He was also a Professor at SUTD and a co-Director of the National Research Foundation-supported Digital Manufacturing and Design Center (DManD).  Prior to joining SUTD, he served as a Program Director (Mechanics of Materials) in the Civil, Mechanical and Manufacturing Innovation Division at the US National Science Foundation, where he was also the Founding Program Director for the Design of Engineering Materials Systems program.  He served the NSF while on leave from the University of Colorado, Boulder (CU) where he was the Associate Dean from Research in the College of Engineering and Applied Science, Chair of the Department of Mechanical Engineering, and a Professor of Mechanical Engineering, holding the Victor Schelke Endowed Chair.

Dunn’s research has focused on understanding the mechanics and physics of complex heterogeneous materials through a combination of theory and experiment, and using this understanding to create methods and tools to design and manufacture new materials and components.  This includes constitutive modeling of the nonlinear multiphysics response (thermal, optical, mechanical) of active polymers and polymer composites, computational design automation approaches based on shape and topology optimization, and additive manufacturing technologies.   Most recently this has involved the development of computational design and manufacturing methodologies for multimaterial additive manufacturing, including the creation of a technology called 4D Printing – an approach that integrates new computational design, manufacturing process, and materials technologies to create environmentally responsive printed components.  Dunn’s  research has been highly impactful: it has been cited over 13,800 times, he has an H-index of 61, and he has received international recognition and awards for his research accomplishments.

Dunn received a PhD in Mechanical Engineering from the University of Washington and held positions at Sandia National Laboratories and the Boeing Company before joining academia.