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Interface

The Optimization Utility software interface is shown below consists of the following elements:

  • File menu
  • Toolbar
  • Properties panel
  • 3D Display
File Menu Toolbar Properties Panel 3D Display

File

The File menu holds the functions to load and save data, also to export it into various formats.

  • New Project - Creates a new Optimization Utility project.
  • Open Project - Loads an Optimization Utility Project that is stored in the WEPX file format on the file system.
  • Save Project - Saves a currently open Optimization Utility Project in the WEPX file format on the file system.
  • Save Project As - Saves a currently open or new Optimization Utility Project in the WEPX file format on the file system after prompting for a project file name.
  • Import Part - Imports a 3D object in the 3MF, STL, SAT and NAS file formats.
    Tip: If the format of your particular file is not among the listed ones, like STEP or IGES, for example, try using Netfabb to convert it into a format that is supported as it understands a significantly larger range of formats.
  • Import Lattice Topology - Imports a custom lattice topology from a WTPL file.
  • Import CBC - Import a Custom Boundary Condition file.

  • Export Component

    • Export Extended Part - Exports an enhanced 3D component including lattice and skin as a 3MF for use in Netfabb's lattice commander.
    • Export Component as Mesh - Export all elements associated with the current component into a single 3MF file.
    • Export Lattice - Exports the lattice part of an enhanced 3D component as a 3MF or STL file to the file system.
    • Export Skin - Exports the skin part of an enhanced 3D component as a 3MF or STL file to the file system.
    • Export Elements - Export all elements associated with the current component into separate files. You will be asked for a folder location.
    • Export Component - Exports the component without distinction of body types.
    Note: These options do not maintain body type association for Netfabb. To keep the association and to work with the exported data in Netfabb directly, use the Export to Netfabb functions in the toolbar.
  • Recent Documents - Lists recently opened project files.
  • Exit - Closes the application.

Toolbar

The toolbar consists of the following items:

Home

Display

  • Default - Sets the 3D display to the default editing mode for the current functional panel.
  • Parts - Displays the currently imported parts in the 3D display.
  • Kernels - Displays the currently define beam (red) and skin (green) kernels.
  • Lattice - Displays the current lattice in the 3D display.
  • Skin - Displays the current skin in the 3D display.
  • Component - Displays the current component in the 3D display.
    • Show COG - Shows the center of gravity of a component in the 3D display (shown as a small green coordinate axis).

FEA

  • Result Cases - Display result cases after simulation or optimization.
  • Stress - Display a component's stresses.
    • Max Target - Displays a component's stresses using a range between 0 and the maximum lattice target stress as defined for optimization.
    • Limited - Displays a component's stresses using a range of 2 standard deviations from the mean stress value.
    • Full Range - Displays a component's stresses using a range between the minimum and maximum stress values.
    • Custom Range - Displays a component's stresses using a custom range.
  • Displacement - Display a component's displacement.
  • Solidity - Display a component's solidity as output from Topology Optimization.

Optimization

  • Show Graphs - Show or hide the optimization graphs.
  • Toggle Graphs - Toggle the display of the optimization graphs from a grid to a panel display.

Actions

  • Create Component - Create a component.
    • Default - Creates the minimal sized component design with kernels applied.
    • Min - Creates the minimal sized component design.
    • Max - Creates the maximal sized component design.
    • Invert - Inverts the thickness when using kernels.
    • Reset - Reset the current component design (deletes the lattice and skin elements).
    • Cancel - Cancels the component creation process without creating lattice or skin elements.
  • Simulate Component - Simulates a component.
    • Solid - Simulates the solid design space (part) under the defined loading conditions.
  • Optimize Component - Optimizes a component.
  • Optimize Topology - Optimizes the topology of a solid assembly.
    • Pause - Pauses the optimization process.
    • Stop - Stops the optimization process at the end of the current iteration, using the results of the optimization process so far.
    • Cancel - Cancels the optimization process without reaching the end of the current iteration, and discards the results of the optimization process.

Camera

  • Reset - Reset the 3D view.
  • Top - Display the top view in the 3D view.
  • Bottom - Display the bottom view in the 3D view.
  • Front - Display the front view in the 3D view.
  • Back - Display the back view in the 3D view.
  • Left - Display the left view in the 3D view.
  • Right - Display the right view in the 3D view.

Selection

  • Select All - Selects all polygons or points on an imported 3D part while editing Surface Regions or Boundary Conditions.
  • Clear - Clears the current polygon or point selection on an imported 3D part while editing Surface Regions or Boundary Conditions.
  • Flood Fill - Selects polygons and points on an imported 3D part which lie within an angle tolerance of a current selection.
  • Tolerance - The angle tolerance to use for a Flood Fill polygon and point selection.

Bundle

Export to Netfabb

  • Extended part information - Writes the current assembly (including the specification of Load Cases and Surface Regions) as a temporary 3MF file and opens it in Netfabb.
  • Topology Optimized Surface - (Topology Optimization only) Writes the generated surface (including the specification of Load Cases) as a temporary 3MF file and opens it in Netfabb.
  • Component - (Lattice Optimization only) Writes the current component as a temporary 3MF file and opens it in Netfabb.
    Note: Components with skin kernels are currently not transferred correctly to Lattice Commander.
  • Components as Mesh - (Lattice Optimization only) Writes the current components as temporary 3MF file and opens it in Netfabb as a mesh.

Settings

Background

  • Black - Changes the background of the 3D display to black.
  • Grey - Changes the background of the 3D display to grey.
  • White - Changes the background of the 3D display to white.
  • Sky Blue - Changes the background of the 3D display to sky blue.

Mesh Resolution

  • Low - Sets the tessellation settings to low resolution.
  • Medium - Sets the tessellation settings to medium resolution.
  • High - Sets the tessellation settings to high resolution.
  • Custom - Sets the tessellation settings to custom and launches a dialog that allows a user to define these settings.

View

  • Status Bar - Display the status bar.
  • Auto Focus - Activates the Auto Focus feature in the Properties Panel. This feature allows for active nodes to be focused by simply clicking them.

(?) Help

  • About Optimization Utility - Displays a dialog that provides information about the Optimization Utility software.

Properties

The Properties panel on the left of the Optimization Utility software consists of the following tabs:

Parts

Displays information relating to imported 3D parts and includes fields for defining properties for lattice, surface regions, lattice kernels and skin kernels. This panel consists of the following elements:

  • Part Name - The settings for lattice and kernels may be imported and exported via a right-click dialog.
    • Part -
      • Type - The type assigned to an imported 3D object including:
        • Lattice (Default) - Can be printed and can contain a lattice or skin and interface with other objects.
        • Solid - Can be printed but cannot contain a lattice or skin. Only Solid parts can be subject to Topology Optimization.
        • Support
        • Non Printing - Cannot be printed and therefore will not contain a lattice or skin.
      • Color - The color assigned to an object when displayed in the 3D view. This color is also used in the Part, Lattice, Skin and Component displays.
      • View - The rendering mode used to display a 3D object including:
        • Flat Shaded (Default)
        • Smooth Shaded
        • Shaded Wireframe
        • Wireframe
        • Transparent
        • Hidden
      • Polygon Count - The number of polygons in the imported part.
      • Surface Area (mm2) - The surface area of the imported part.
      • Volume (mm3) - The volume of the imported part.
      • Bounding Box - The bounding box size of the part.
        • X (mm) - The size along the x axis
        • Y (mm) - The size along the y axis
        • Z (mm) - The size along the z axis
      • Mesh Quality - The quality of the imported mesh.
        • Good - Suitable for lattice creation and FEA simulation.
        • Inaccurate for FEA - Suitable for lattice creation however FEA simulation may be inaccurate for Solid and Skin elements.
        • Invalid for FEA - Suitable for lattice creation only.
        • Bad - Not suitable for lattice creation or FEA simulation.
    • Lattice
      • If enabled, a lattice will be created as part of a component.
        Note: You may sometimes see a `Multiple Lattice Groups Detected' message shown in the 3D display. If shown, please ensure a skin is defined which connects all groups as this is required for FEA simulation.
      • Unit Size - The size in mm of lattice units along the X, Y and Z axes.
      • Thickness - The thickness of lattice beams. This can be defined as:
        • Uniform - The same thickness is used for all lattice beams as defined in the Value field.
        • Value (mm) - The uniform thickness value.
        • Variable - The thickness used for each lattice beam will depend on defined Lattice Kernels. The thickness values will also be based on defined Threshold, Minimum, and Maximum thickness settings.
          Note: A preview of the current lattice will be shown if a component has been created. This preview will update immediately when Threshold , Minimum, and Maximum beam thickness values are changed.
        • Threshold - The threshold thickness is the minimum thickness a lattice beam must have in order to be valid. Invalid beams have a thickness of 0 and are therefore not created.
        • Minimum - The minimum thickness value for a lattice beam.
        • Maximum - The maximum thickness value for a lattice beam.
      • Offset - The offset in mm to apply to lattice units along the X, Y, and Z axes.
      • Lattice Topology - The lattice topology to use:
        • See Available Lattice Topologies for the full list.
        • New… launches the Autodesk® Lattice Topology Utility for Netfabb® where new lattice topologies can be defined. See Creating New Lattice Topologies for further information.
      • Surface Trim - Trims a lattice to the surface of the part using the following approaches:
        • Off - No trim is applied to the lattice.
        • Basic - Trims a lattice to the surface without altering the shape of beams or junctions connecting to the surface.
        • Intermediate - Trims a lattice to the surface and ensures beam ends are clipped so as to lie on the surface if they protrude outside the surface. Junctions are left intact.
        • Advanced - Trims to the surface ensures that any parts of the lattice, beams or junctions, that lie outside the surface are clipped and repositioned to lie on the surface.
      • Meshing Method
        • Legacy - The default setting. Produces single shell lattices for Grid, X, Star, and W topologies and multi-shell lattices for all other topologies.
          Note: Certain thickness ranges (very thick beams) will force this method to produce multi-shell lattices for X, Star, and, W topologies.
        • New - Produces single shell lattices.
          Note: This is a beta feature and there may be limitations imposed when using this feature with some lattice settings).
      • Beam Profile - The beam profile of lattice beams for the Legacy meshing method including:
        • Quad (default, 4 sided)
        • Hexagon (6 sided)
        • Octagon (8 sided)
      • Beam Side Count - The number of sides used to define a beam for the New meshing method.
      • Unit Distribution
        • Legacy - The default setting.
        • New - Provides greater flexibility for positioning custom topology lattices in a design space.
      • Modifications - Modifies a basic or advanced lattice as follows:
        • Randomize - Creates a random lattice by randomly displacing lattice junctions when calculated. This modification has the following settings:
          • Off (default) - No randomization is applied.
          • Min - A minimum randomization is applied.
          • Med - A medium randomization is applied.
          • Max - A maximum randomization is applied.
        • Conform - Creates a conformed lattice that follows the horizontal profile of a 3D object. This modification has the following settings:
          • Off (default) - No conforming is applied.
          • Top (-Straight/Curved) - The conformed lattice matches the object's top profile.
          • Mid (-Straight/Curved) -The conformed lattice matches the object's mid profile.
          • Bottom (-Straight/Curved) - The conformed lattice matches the object's bottom profile.
          • Adaptive (-Straight/Curved) - The conformed lattice matches the object's top, mid and bottom profile.
            Note: The conform feature will only work with the Grid, X, Star, W, and Column topologies.
        • Smooth - Smoothens a lattice mesh:
          • Off - No smoothing is applied.
          • Coarse - A coarse smoothing is applied.
          • Fine - A fine smoothing is applied.
          • Note: This feature is only functional for single shell lattices.
        • Large Junctions - Creates a lattice with large junctions:
          • Off - No chunky junctions are created.
          • On - Chunky junctions are created.
          • Note: This feature is only available with the Legacy meshing method and functional for the Grid, X, Star, and W lattice topologies.
    • Surface Regions
      • If enabled, the surface region will be used as part of creating a component.
      • Skin Region - The main node of a region. Multiple regions can be defined for an imported part and consist of the following:
        • Name - The name of the region.
        • Number of Polygons - Polygon count of the region.
        • Type - The type of the region defined as one of the following:
          • Boolean (default) - A trimming region.
            Note: All unselected regions on a part surface are treated as Boolean surface regions.
          • Hollow - A non-interfacing region on a surface. Lattice beams connecting to these regions are deleted.
          • Solid - A region where a solid is defined. Lattice beams extend into solid regions to ensure good connectivity.
          • Skin - A skin or layer region of a surface with a thickness defined as Uniform or Variable as described below.
          • Skin Type - A skin type defined when a region is set to have a Skin type and includes the following values:
            • In (default) - Skins are projected inwards from an object surface.
            • Out - Skins are projected outwards from an object surface.
            • Solid Interface - Similar to rough skins but can only be defined with uniform thickness values. These skins are useful if a lattice interfaces with a solid part.
              • Note: Adjacent In and Out skin regions create a Boolean surface border i.e. adjacent polygons from both regions will have a Boolean type and no Skin will be created in this section of both regions.
          • Thickness - The thickness of the skin type defined as:
            • Uniform - As defined for lattice thickness but instead for a skin region.
            • Variable - As defined for lattice thickness but instead for a skin region. Skin kernels define the thicknesses of skin surface regions.
              • Note: A preview of the current skin will be shown if a component has been created. This preview will update immediately when Threshold, Minimum, and Maximum skin thickness values are changed.
      • Smooth Skin - Smoothens a skin mesh.
        • Off - No smoothing is applied.
        • Coarse - A coarse smoothing is applied.
        • Fine - A fine smoothing is applied.
      • Subdivide Skin - Controls how fine the skin is meshed.
        • Off - Skin mesh is very coarse.
        • Coarse - Skin mesh is coarse.
        • Fine - Skin mesh is fine.
      • Preserve Sharp Edges - Controls whether sharp edges on unselected faces of a skin are preserved when smoothing a skin.
        • Off - Sharp edges are not preserved.
        • On - Sharp edges are preserved.
      • To select regions on a surface:
        • Select - Click on Ctrl + Left mouse and drag to select a surface region.
        • Unselect - Click on Shift + Left mouse button and drag to remove a selection.
    • Lattice Kernels - Defines lattice kernels for variable lattice beam thicknesses. The settings may be imported and exported via a right-click dialog. Settings include the following:
      • If enabled, the kernel will be used to define the variable beam thickness of the lattice.
      • Kernel - The main node of a lattice kernel. Multiple kernels can be defined for an imported part and consist of the following:
        • Name - The name of the lattice kernel.
        • Position - The position of the lattice kernel.
          • X (mm) - The X axis position.
          • Y (mm) - The Y axis position.
          • Z (mm) - The Z axis position
        • Size - The size of the lattice kernel defining the bound of the kernel where the defined peak value has half its defined value.
          Note: Kernels are density functions which define a thickness value for lattices and skins. The size therefore defines the bound of the density function.
          • X (mm) - The size along the X axis.
          • Y (mm) - The size along the Y axis.
          • Z (mm) - The size along the Z axis.
        • Angle - The angle of the lattice kernel.
          • X (mm) - The angle orientation relative to the X axis.
          • Y (mm) - The angle orientation relative to the Y axis.
          • Z (mm) - The angle orientation relative to the Z axis.
        • Peak (mm) - The peak value of the kernel.
        • Kernel Type
          • Gaussian - Kernel has bell curve effect with distance.
          • Linear - Kernel has linearly decreasing effect with distance.
          • Uniform Kernel has uniform effect with distance.
        • Kernel Effect
          • Thickness - Kernel increases lattice thickness.
          • Spatial - Kernel increases lattice node spacing.

    • Skin Kernels - Defines skin kernels for variable skin surface regions. These kernels are defined in the same way as lattice kernels as described above but only affect variable surface regions. Please refer to the lattice kernels description for further information on how to sets kin kernel values. The settings may be imported and exported via a right-click dialog.

Simulation

Displays simulation criteria for imported solid parts, lattices and skins including:

  • FEA Package - Lists the available FEA packages to select from. Currently can only be Autodesk® Nastran if it is installed on a machine.
  • Perform LSBA - Controls if a Linear Static Buckling Analysis should be performed as part of the simulation.
  • Use CBC File - Determines if Optimization Utility should look for a Custom Boundary Conditions file with the same name of the project and use it for simulation and optimization.
  • Parts - List of parts and their materials.
    • Workspace - Lists the available 3D printer workspaces provided with the software for FEA simulation. A workspace should be selected from this list.
      • Select Custom workspace to enable a custom material.
    • Material - Lists the materials that are available in the chosen workspace. A material should be selected for each part from this list.
      • If Custom workspace is selected, properties for a custom material can be set here. A material for FEA is defined by two properties:
        • Young's Modulus (MPa)
        • Poisson Ratio
    • Solid With Cavity - Defines whether this part, if solid, has a cavity.
      • On - has a cavity
      • Off - has no cavity
  • Load Cases - Lists the currently specified load cases.
    • Load Case - Defines a load case
      • Name - The load case's name, which can be edited.
      • Checkbox - Enables or disables a load case to be included or excluded from the analysis.
      • Boundary Condition - Defines a boundary condition.
        • Checkbox - Enables or disables a boundary condition.
        • Name - The name of the boundary condition, which can be edited.
        • Boundary Condition Type - The type of the boundary condition including:
          • Pressure - Defines a pressure boundary condition on surfaces.
          • Restraint - Defines a restraint boundary condition on nodes.
          • Force - Defines a force boundary condition on nodes.
        • To define a Boundary Condition:
          • Select - Click on Ctrl + Left mouse and drag to apply a boundary condition to triangles or points.
          • Unselect - Click on Shift + Left mouse button and drag to remove a boundary condition from triangles or points.
      • No. of Polygons/Points - The number of selected polygons when defining a pressure boundary condition.
      • Surface Area - The surface area of selected polygons in mm2.
      • Pressure Type - The type of pressure including:
        • Normal Pressure - Always in the direction perpendicular to the surface (positive direction is away from the surface).
        • Global Pressure - It is always in the direction given by the pressure vector.
      • No. of Points - The number of selected points when defining a restraint or force boundary condition.
      • Free Movement - Defines whether restraint nodes are free to move in X, Y or Z axes.
      • Free Rotation - Defines whether restraint nodes are free to move in X, Y or Z axes.
      • X (Pa) - X component of the pressure vector in Pascals.
      • Y (Pa) - Y component of the pressure value in Pascals.
      • X (Pa) -Z component of the pressure value in Pascals.
      • X (N) - X component of the force vector in Newtons.
      • Y (N) - Y component of the force vector in Newtons.
      • X (N) - Z component of the force vector in Newtons.
      • Distribute Force Across Nodes - Defines whether a force should be uniformly distributed across selected nodes or the force vector be applied to every node.

Optimization

Defines optimization settings used to optimize a component based on the defined load criteria (in the Simulation tab). The settings are different for Lattice Optimization and Topology Optimization, respectively. These common settings include:

  • Optimize - Defines the kind of optimization that should be performed:
    • Lattice & Skin
    • Lattice
    • Skin
    • Topology
  • Max Optimization Time (mins) - The maximum duration of the optimization process in minutes.
  • Max Optimization Iterations - The maximum number of iterations.
  • Screen Capture - Defines whether to capture the screen at the end of every iteration of the optimization process:
    • Application - Captures the application window only.
    • None - Screen is not captured.
  • Keep - Defines which solution should be kept as the final result of the optimization:
    • Best Solution - Keep the best optimization solution (component).
    • Last Solution - Keep the last optimization solution (component).

Lattice Optimization

If either Lattice & Skin, Lattice, or Skin are selected for Optimize, the following options are available:

  • Initial Verification - Defines whether initial verification checks should be carried out including:
    • Solid - Solid verification of an imported part, checks if the design space, filled with solid material, can stand the loading. Otherwise it stops the optimization.
    • Min - Minimum thickness component verification, checks if the design with minimum thickness for all variable thickness lattices and skins can stand the loading, and stops the optimization if so.
    • Max - Maximum thickness component verification, checks if the design with maximum thickness for all variable thickness lattices and skins can stand the loading. Otherwise it stops the optimization.
  • Stress Averaging
    • Skin Averaging - Determines the stress calculation of skin elements. Stress values are originally calculated for each skin mesh element. Skin mesh nodes have many coincident mesh element vertices.
      • On (default) - The overall stress value at each node of a skin mesh element is calculated by taking the average of the stress values of the coincident elements.
      • Off - The stress value at each node of a skin mesh element is directly captured from stress values of that element.
  • Component - Optimization properties related to the whole component:
    • Target Volume (mm3) - The overall target volume for the optimization in cubic millimeters. Optimization will stop if this target is met and all the constraints are also met. If set to zero, it will never stop the optimization.
    • Target Maximum Displacement (mm) - An overall target maximum displacement used when volume and displacements are used as stopping criteria in MiniOpt.
    • Lattice Maximum Allowable Stress (Pa) - The maximum permitted stress value of the associated part’s lattice, as a constraint for the optimization.
    • Lattice Stress Importance - A positive value that determines the relative importance of the associated Lattice Maximum Allowable Stress. Higher values indicate greater importance. The default value is 1.0.
    • Skin Maximum Allowable Stress (Pa) - The maximum permitted stress value of the skin region, as a constraint for the optimization.
    • Skin Stress Importance - A positive value that determines the relative importance of the associated Skin Maximum Allowable Stress. Higher values indicate greater importance. The default value is 1.0.
  • Optimization Algorithm
    • Algorithm - List of the available optimization algorithms.
      • MiniOpt - The mini optimization algorithm. It gives a relatively progressive optimization of the component to meet the constraint while trying to minimise the volume.
      • KernelOpt - The kernel optimization algorithm. It uses a stochastic approach to optimizing the properties of the lattice and skin kernels defined by the user to meet the constraints while minimising the volume. KernelOpt is designed to work mainly with Gaussian thickness kernels although it may work well with the other kernel types. For best results, please define a sufficient number of kernels for skins and lattices with sensible sizes and peak values and then optimize their properties using the KernelOpt algorithm. This algorithm is particularly useful when you need to preserve symmetries while optimizing the design, which can be achieved using kernels.
    • LBSF Interval (for MiniOpt) – Defines the frequency of the Linear Buckling Safety Check during optimization, e.g. every 10 optimization iterations. For checking the linear buckling in every iteration use a value of 1. Zero means never perform a buckling check during optimization.
    • LBSF Check (for KernelOpt) – Determines if the Linear Buckling Safety Check is performed during optimization in every iteration.
    • Stopping Criteria (for MiniOpt) – Optimization ends when these criteria are satisfied:
      • Volume and Stress.
      • Volume and Displacement.
    • Variables (for KernelOpt) - Defines the optimization variables: the kernel properties that are adjusted by the KernelOpt algorithm:
      • Peaks: Only peak values of the kernels are adjusted.
      • Peaks and Sizes: Only peak values and sizes of the kernels are adjusted.
      • Peaks, Sizes, Positions, and Directions: All kernel properties except their types are adjusted.

Topology Optimization

If Topology is selected for Optimize, the following options are available:

  • Constraints – Defines lower and upper bounds for responses, i.e. representative quantities of the part assembly.
    • Response – Possible responses are:
      • Maximum Displacement – The maximum displacement of any point in the part assembly (mm)
      • Total Mass – The total mass of the part (relative to total initial mass).
      • Compliance – The maximal compliance of the part (1/Pa).
      • Maximum Force at Restraints – The maximal forces at the restraint points within the part (N).
      • Maximum Stress – The maximum stress within the assembly (Pa).
    • Objective – Defines the response that will be minimized by the Topology Optimization.
    • Variable Parts – Defines which parts are subject to Topology Optimization and which parts are to be considered fixed.
      Note: At least one part in an assembly must be variable.
    • Advanced Options – Specify Topology Optimization engine options
      • Initial Solidity – Defines the initial value of the solidity used in the first iteration of the Topology Optimization.
      • Use Custom MMS – Enables the definition of a custom Minimal Member Size (MMS). The minimal member size refers to the smallest internal diameter of the optimized part. Disabling this options uses three levels of adjacent tetrahedral elements as minimal member size.
      • Minimal Member Size – Defines the minimal size of individual members of the optimized part (in mm). A value below 1.2 times the longest tetrahedral element size will be automatically limited to this threshold.
      • Relative Change – Defines the maximal change of the solidity per iteration. Larger values can increase the speed of the iteration process. If this value is too high, the Topology Optimization process might not converge at all.
  • Surface Generation - Specify options for surface generation.
    • Threshold – All points with Solidity above the Threshold will be considered solid in the surface generation, all other points will be discarded.
    • Interpolated Surface – Enable/disable the generation of a smoother surface by interpolating a smoother surface between tetrahedral faces.
    • Surface Threshold Tolerance – (Interpolated Surface only) Adjustment parameter to avoid thin triangles in the generated surface.

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