[Submitted on 8 Sep 2025]
Authors:Pablo Antolin, Michael Barton, Georges-Pierre Bonneau, Annalisa Buffa, Amaia Calleja-Ochoa, Gershon Elber, Stefanie Elgeti, Gaizka Gómez Escudero, Alicia Gonzalez, Haizea González Barrio, Stefanie Hahmann, Thibaut Hirschler, Q Youn Honga, Konstantin Key, Myung-Soo Kim, Michael Kofler, Norberto Lopez de Lacalle, Silvia de la Maza, Kanika Rajain, Jacques Zwar
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Abstract:With the evolution of new manufacturing technologies such as multi-material 3D printing, one can think of new type of objects that consist of considerably less, yet heterogeneous, material, consequently being porous, lighter and cheaper, while having the very same functionality as the original object when manufactured from one single solid material. We aim at questioning five decades of traditional paradigms in geometric CAD and focus at new generation of CAD objects that are not solid, but contain heterogeneous free-form internal microstructures. We propose a unified manufacturing pipeline that involves all stages, namely design, optimization, manufacturing, and inspection of microstructured free-form geometries. We demonstrate our pipeline on an industrial test case of a blisk blade that sustains the desired pressure limits, yet requires significantly less material when compared to the solid counterpart.
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