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Because of the anisotropy of the process and the variability in the quality of printed parts, finite element analysis is not directly applicable to recycled materials manufactured using fused filament fabrication. The purpose of this study is to investigate the numerical-experimental mechanical behavior modeling of the recycled polymer, that is, recyclable polyethylene terephthalate (rPET), manufactured by a deposition FFF process under compressive stresses for new sustainable designs.

In all, 42 test specimens were manufactured and analyzed according to the ASTM D695-15 standards. Eight numerical analyzes were performed on a real design manufactured with rPET using Young's compression modulus from the experimental tests. Finally, eight additional experimental tests under uniaxial compression loads were performed on the real sustainable design for validating its mechanical behavior versus computational numerical tests.

As a result of the experimental tests, rPET behaves linearly until it reaches the elastic limit, along each manufacturing axis. The results of this study confirmed the design's structural safety by the load scenario and operating boundary conditions. Experimental and numerical results show a difference of 0.001–0.024 mm, allowing for the rPET to be configured as isotropic in numerical simulation software without having to modify its material modeling equations.

The results obtained are of great help to industry, designers and researchers because they validate the use of recycled rPET for the ecological production of real-sustainable products using MEX technology under compressive stress and its configuration for numerical simulations. Major design companies are now using recycled plastic materials in their high-end designs.

Validation results have been presented on test specimens and real items, comparing experimental material configuration values with numerical results. Specifically, to the best of the authors’ knowledge, no industrial or scientific work has been conducted with rPET subjected to uniaxial compression loads for characterizing experimentally and numerically the material using these results for validating a real case of a sustainable industrial product.

Hydrothermal waves represent the preferred mode of instability of the so-called Marangoni flow for a wide range of liquids and conditions. The related features in classical rectangular containers have attracted much attention over recent years owing to the relevance of these oscillatory modes to several techniques used for the production of single crystals of semiconductor or oxide materials. Control or a proper knowledge of convective instabilities in these systems is an essential topic from a material/product properties saving standpoint. The purpose of this study is to improve our understanding of these phenomena in less ordinary circumstances.

This short paper reports on a numerical model developed to inquire specifically about the role played by sudden changes in the available cross-section of the shallow cavity hosting the liquid. Although accounting for the spanwise dimension would be necessary to derive quantitative results, the approach is based on the assumption of two-dimensional flow, which, for high-Pr fluids, is believed to retain the essence of the involved physical processes.

Results are presented for the case of a fluid with Pr = 15 filling an open container with a single backward-facing or forward-facing step on the bottom wall or with an obstruction located in the centre. It is shown that the presence of steps in the considered geometry can lead to a variety of situations with significant changes in the local spectral content of the flow and even flow stabilization in certain circumstances. The role of thermal boundary conditions is assessed by considering separately adiabatic and conducting conditions for the bottom wall.

Although a plethora of studies have been appearing over recent years motivated, completely or in part, by a quest to identify new means to mitigate these instabilities and produce accordingly single crystals of higher quality for the industry, unfortunately, most of these research works were focusing on very simple geometries. In the present paper, the causality and interdependence among all the kinematic and thermal effects mentioned above is discussed.

IN order to keep this introductory article on the Concorde supersonic airliner within reasonable bounds and within the general sphere of interest of readers of this journal, I propose to begin with a brief description of the aeroplane itself and an outline of its development history, and then to deal rather more fully with the engineering organisation which has been built up on this major bi‐national project.

THE ATTENTION which has been paid in both the lay and technical press to the Concorde has revealed the many problems associated with the design and construction of aircraft flying at supersonic speeds. They relate to both aerodynamic design and the materials of construction where, particularly for the latter, one of the main influencing factors is the high surface temperature caused by skin friction. In the case of the Concorde which, it is stated, has a mximum speed of Mach 2‐2 and will fly for some 60 per cent of the time at a cruising speed of Mach 2‐1, the airframe can still be made mainly from conventional aluminium alloy as are today's jets. But the surface temperature starts to rise rapidly as speed exceeds Mach 2‐2 and this will mean that before long aluminium alloys will have to be replaced by harder metals with higher weight‐to‐strength ratio, for example titanium or stainless steel alloys. At the same time it is known that surface temperatures will range from, say, minus 65°F to 450°F with some—areas e.g., engine mounts—well above 1000°F.

This study aims at enhancing the performance of a 16-stage axial compressor and improving the operating stability. The adopted approaches for upgrading the compressor are artificial neural network, optimization algorithms and computational fluid dynamics.

The process starts with developing several data sets for certain 2D sections by means of training several artificial neural networks (ANNs) as surrogate models. Afterward, the trained ANNs are applied to the 3D shape optimization along with parametrization of the blade stacking line. Specifying the significant design parameters, a wide range of geometrical variations are considered by implementation of appropriate number of design variables. The optimized shapes are analyzed by applying computational fluid dynamic to obtain the best geometry.

3D optimal results show improvements, especially in the case of decreasing or elimination of near walls corner separations. In addition, in comparison with the base geometry, numerical optimization shows an increase of 1.15 per cent in total isentropic efficiency in the first four stages, which results in 0.6 per cent improvement for the whole compressor, even while keeping the rest of the stages unchanged. To evaluate the numerical results, experimental data are compared with obtained data from simulation. Based on the results, the highest absolute relative deviation between experimental and numerical static pressure is approximately 7.5 per cent.

The blades geometry of an axial compressor used in a heavy-duty gas turbine is optimized by applying artificial neural network, and the results are compared with the base geometry numerically and experimentally.

Introduces papers from this area of expertise from the ISEF 1999 Proceedings. States the goal herein is one of identifying devices or systems able to provide prescribed performance. Notes that 18 papers from the Symposium are grouped in the area of automated optimal design. Describes the main challenges that condition computational electromagnetism’s future development. Concludes by itemizing the range of applications from small activators to optimization of induction heating systems in this third chapter.

This paper aims to investigate the feasibility of supportless printing of lattice structures by metal fused filament fabrication (MF³) of Ti-6Al-4V. Additionally, an empirical method was presented for the estimation of extrudate deflection in unsupported regions of lattice cells for different geometric configurations.

Metal-polymer feedstock with a solids-loading of 59 Vol.% compounded and extruded into a filament was used for three-dimensional printing of lattice structures. A unit cell was used as a starting point, which was then extended to multi-stacked lattice structures. Feasible MF³ processing conditions were identified to fabricate defect-free lattice structures. The effects of lattice geometry parameters on part deflection and relative density were investigated at the unit cell level. Computational simulations were used to predict the part quality and results were verified by experimental printing. Finally, using the identified processing and geometry parameters, multi-stacked lattice structures were successfully printed and sintered.

Lattice geometry required considerable changes in MF³ printing parameters as compared to printing bulk parts. Lattice cell dimensions showed a considerable effect on dimensional variations and relative density due to varying aspect ratios. The experimental printing of lattice showed large deflection/sagging in unsupported regions due to gravity, whereas simulation was unable to estimate such deflection. Hence, an analytical model was presented to estimate extrudate deflections and verified with experimental results. Lack of diffusion between beads was observed in the bottom facing surface of unsupported geometry of sintered unit cells as an effect of extrudate sagging in the green part stage. This study proves that MF³ can fabricate fully dense Ti-6Al-4V lattice structures that appear to be a promising candidate for applications where mechanical performance, light-weighting and design customization are required.

Supportless printing of lattice structures having tiny cross-sectional areas and unsupported geometries is highly challenging for an extrusion-based additive manufacturing (AM) process. This study investigated the AM of Ti-6Al-4V supportless lattice structures using the MF³ process for the first time.

An aerodynamic shape optimization algorithm is presented, which includes all aspects of the design process: parameterization, flow computation and optimization. The purpose of this paper is to show that the Class‐Shape‐Refinement‐Transformation method in combination with an Euler/adjoint solver provides an efficient and intuitive way of optimizing aircraft shapes.

The Class‐Shape‐Transformation method was used to parameterize the aircraft shape and the flow was computed using an in‐house Euler code. An adjoint solver implemented into the Euler code was used to compute the required gradients and a trust‐region reflective algorithm was employed to perform the actual optimization.

The results of two aerodynamic shape optimization test cases are presented. Both cases used a blended‐wing‐body reference geometry as their initial input. It was shown that using a two‐step approach, a considerable improvement of the lift‐to‐drag ratio in the order of 20‐30 per cent could be achieved. The work presented in this paper proves that the CSRT method is a very intuitive and effective way of parameterizating aircraft shapes. It was also shown that using an adjoint algorithm provides the computational efficiency necessary to perform true three‐dimensional shape optimization.

The novelty of the algorithm lies in the use of the Class‐Shape‐Refinement‐Transformation method for parameterization and its coupling to the Euler and adjoint codes.

This paper deals with structural shape optimization of vibrating prismatic shells and folded plates. The finite strip method is used to determine the natural frequencies and modal shapes based on Mindlin‐Reissner shell theory which allows for transverse shear deformation and rotatory inertia effects. An automated optimization procedure is adopted which integrates finite strip analysis, parametric cubic spline geometry definition, automatic mesh generation, sensitivity analysis and mathematical programming methods. The objective is to maximize the fundamental frequency by changing thickness and shape design variables defining the cross‐section of the structure, with a constraint that the total volume of the structure remains constant. A series of examples is presented to highlight various features of the optimization procedure as well as the accuracy and efficiency of finite strip method.

This paper aims to address the development and implementation of “AltPrint,” a slicing algorithm based on a new filling process planning from a variation in the deposited material geometry. AltPrint enables changes in the extruded material flow toward local variations in stiffness. The technical feasibility evaluation was conducted experimentally by fused filament fabrication (FFF) process of snap-fit subjected to a mechanical cyclical test.

The methodology is based on the estimation of the parameter E from the mathematical relationships among the variation of the material in the material flow, nozzle geometry and extrusion parameters. Calibration, validation and analysis of the printed specimens were divided into two moments, of which the first refers to the material responses (flexural and dynamic mechanical analysis) and the second involves the analysis of the printed components with localized flow properties (for estimating the response to cyclic loading). Finite element analysis assisted in the comparison of two snap-fit geometries, one traditional and one generated by AltPrint. Finally, three examples of compliant mechanisms were developed to demonstrate the potential of the algorithm in the generation of functional prototypes.

The contribution of AltPrint is the variable fill width integrated with the slicing software that varies the print parameters in different regions of the object. The alternative extrusion method based on material rate variation was conceived as an “open software” available in GitHub platform, hence, open manufacturing with initial focus on desktop 3D printer based on FFF. The slicing method provides deposited variable-width segments in an organized and replicable filling strategy, resulting in mechanical properties variations in specific regions of a part. It was implemented and evaluated experimentally and indicated potential applications in parts manufactured by the additive process based on extrusion, which requires local flexibilities.

This paper presents a new alternative method for application in an open additive manufacturing context, specifically for additive extrusion techniques that enable local variations in the material flow. Its potential for manufacturing functional parts, which require flexibility due to cyclic loading, was demonstrated by fabrication and experimental evaluations of parts made in acrylonitrile butadiene styrene filament. The changes proposed by AltPrint enable geometric modifications in the response of the printed parts. The proposed slicing and filling control of parameters is inserted in a context of design for additive manufacturing and shows great potential in the area of product design.