213.2.3 - Generative Design

Generative Design Criteria

Objectives & Limits

There are two primary objective types you can shoot for when setting up a Generative Study:
1. Maximize Stiffness. Achieves the maximum possible stiffness of the design for a given mass. With this objective, the design resists displacement caused by specified constraints and loads, but may be heavier.
2. Minimize Mass. Achieves the minimum possible mass of the design. With this objective, the resulting shape is light, but may be more prone to deflections caused by specified constraints and loads.
You can also apply additional constraints known as limits, which include:
1. Safety Factor. Enables you to specify the ratio between the material’s yield strength and the maximum von Mises stress that the outcomes should satisfy. The Safety Factor value is based on the Yield Strength value of the material selected in your study.
2. Mass Target. Enables you to achieve the desired mass of the generated shape.
3. Displacement. Enables you to include displacement limits in the generative design process, which can be applied globally (to the entire design) or locally (to certain areas of the design).

Manufacturing Methods

You can select one or more Manufacturing Methods when creating a Generative Study, which will optimize your design for manufacturability within specific process types as well as with accessibility of tooling from specific direction(s)
The Manufacturing Methods you can apply - in order of increasing manufacturing complexity - include:
- 2-Axis Cutting. One of the simplest and most efficient manufacturing methods, requiring very minimal programming, 2D cutting parameters include cutting direction(s) and minimum wall thickness.
- 2.5-Axis Milling. A very common manufacturing method, requiring average CNC programming, includes parameters of tool direction, minimum tool diameter, and minimum wall thickness.
- 3-Axis Milling. A less common manufacturing method, requiring more lengthy programming methods, includes parameters of tool direction, minimum tool diameter, tool shoulder length, and (toolholder) head diameter)
- 5-Axis Milling. A rare manufacturing method, requiring extensive programming methods; includes parameters of minimum tool diameter, tool shoulder length, and (toolholder) head diameter.
- Die Casting. A common, yet involved manufacturing method, requiring upfront investment in the design and creation of production tooling, typically meant for large production quantities; includes parameters of min/max part thickness, draft angle, and pull direction.
- Additive. Depending on the additive process, this can be either extremely complex & costly (ex: Metal DED) or extremely efficient and affordable (ex: Plastic FDM). 3D-Printing has some of the fewest manufacturability constraints possible, but there are still parameters related to print orientation (due to anisotropic properties), overhang angles, and minimum (bead) thickness.
- Unrestricted. This method has no manufacturability constraints, and should only be used when initially exploring design possibilities, and should not be used when generating final designs.

Materials

You can select multiple material types for your Generative Study, which will increase the number of outcomes for you to explore
Generative Design will only account for the physical strengths of materials, but will not account for:
- Chemical Properties. Chemical properties dictate how a material will react under certain conditions or with other substances. This can impact corrosion resistance, flammability, and other chemically-induced behaviors.
  - Not considering chemical properties could lead to material failures in environments with aggressive agents, or when materials are exposed to certain chemicals during their lifecycle.
- Material (in)Compatibility. Different materials might react adversely when in contact with each other, leading to corrosion, galvanic reactions, or other detrimental effects.
  - Ignoring material compatibility can result in decreased lifespan of the product, increased maintenance costs, and potential safety hazards. It's crucial to ensure chosen materials can coexist without causing harm to each other or the overall design.
- Material Manufacturability. Manufacturability refers to the ease with which a material can be converted into a finished product. This includes considerations like machining, welding, casting, and forming capabilities.
  - Selecting a material that has great physical properties but is difficult to manufacture can escalate production costs, lead to longer production times, and require specialized equipment or expertise. It's essential to strike a balance between a material's desirable properties and its manufacturability.
For these reasons, a comprehensive approach that does not just rely solely on inputs and outputs of Generative Design is required for proper engineering and manufacturing of Generatively-Designed parts.

2.3✔ CHECKPOINT

Door Hook Study Criteria

For this Checkpoint you will determine and apply design and manufacturing criteria to your Generatively-Designed Door Hook
- Your Generatively Designed door hook will be 3D-Printed from PET-G filament using an FDM printer - assign criteria accordingly

- Once done, upload documentation of your progress (text/pictures/gifs/videos) to your previously-created "Generative Door Hook" project page on your portfolio website, including:
  1. Descriptions/summaries of what you did/learned

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