Wearables design P34 Siemens NX 7.

0 P40
Luxion KeyShot 8 P37 Siemens Femap 12 P41

TECHNOLOGY FOR THE PRODUCT LIFECYCLE NOVEMBER 2018 | £6 | € 7 | $10 | DEVELOP3D.COM

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DICTAPHONE DESIGN PROTOTYPING GLASS ANALYSIS AND OPTIMISATION

p01_D3D_NOV18_COVER rb.indd 1 09/11/2018 12:08
 WELCOME
EDITORIAL
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A
DESIGN/PRODUCTION
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greg@x3dmedia.com s the first order of business this month, I wanted to say
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 2019

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 CONTENTS

NOVEMBER 2018 ISSUE NO. 104

7 NEWS
XJet ramps up its additive manufacturing offering, AMD
releases details of 64-core ‘Rome’ CPU and GE gets
green light to use 3D-printed part in aircraft engines

FEATURES
12 Visual Design Guide: Olympus DS-9500 dictaphone
14 COVER STORY Robocar’s race for autonomy
23 Computed tomography shines bright at Nordic Lights
29 Art of glass: beer bottle prototypes by Orora
31 Kyungshin adopts topology optimisation for engine parts
34 STMicroelectronics limbers up for wearables challenge

REVIEWS
36 Luxion Keyshot 8.0
41 Siemens PLM Femap 12

45 DEVELOP3D SERVICES

46 THE LAST WORD

Al Dean considers the future of transportation and
how designs for tomorrow’s vehicles could be radically
different from those of their predecessors

2019

17 April 2019
The wood used to produce this magazine
comes from Forest Stewardship Council
Sheffield University
certified well-managed forests, controlled
sources and/or recycled material

DEVELOP3D.COM NOVEMBER 2018 5

p05_D3D_NOV18_Contents - jlt FINAL.indd 5 09/11/2018 13:39

 NEWS PRODUCT DEVELOPMENT NEWS

XJET RAMPS
UP ITS AM
OFFERING WITH
NEW VERSATILE
CERAMIC
MATERIAL
» Alumina ceramic material, water
soluble supports, promise of
metals in 2019 and new clients add
to company’s boosted presence in
3D printing market

X
Jet has continued to build on its nano-particle
jetting approach to 3D printing, announcing a new
ceramic material aimed at the engineering sector
and developments on its soluble support material.
Launched as a commercial product only a year
ago, its Carmel 1400 system is capable of building parts
in ceramics and metals.In the future, it may be capable of
combining the two maerials in a single
printed part.
Already producing high-resolution, 99.95% dense ceramic
parts from Zirconia, the new ceramic material Alumina offers
a wider range of engineering uses, faster builds, and more
opportunities to manipulate the part while in both its ‘green’
and fired states.
It’s an intriguing approach to 3D printing, based on jetting
nano-particles of materials much smaller than those seen in
traditional powder bed processes. This enabled by suspending
the particles in a liquid (which evaporates in the 300°C build
chamber), and building up the layers to form parts.
The updated soluble support materials can now be removed
using little more than a water-based solution bath, with any
delicate geometry or fine details unlikely to be damaged during
the removal process.
The Carmel system is capable of printing parts at resolutions
of 3 to 8 microns for metals and 10 to 15 microns for zirconia, an
astonishingly high resolution when compared to the typical 50 upgraded its manufacturing set-up, allowing it to increase
microns per layer for most metals SLS-type methods, or the 50 to output considerably.
100 microns offered by HP’s Metal Jet binder jetting. Much of the research and development work is taking place at
The density of parts achieved by this method is likely to attract XJet’s new $10M Additive Manufacturing Centre, which held its
a lot of interest, and while figures have not yet been revealed, public opening last month in Rehovot, Israel.
XJet CEO Hanan Gothait explained to us that the final product is One of the largest facilities of its kind in the world, the new
‘much healthier’ than parts made by other means and easier to 8,000-square foot R&D centre has 9 Carmel systems running
(Top) Xjet’s
simulate accurately, thanks to the isotropic nature of the nano- full time for testing, quality assurance and new material and new Additive
particle shrinkage. technology development across both ceramics and metals. Manufacturing Centre
XJet’s metals 3D printers are set to launch in 2019, with the With a maximum space for 12 test machines, XJet expects it will in Israel is home to the
company claiming it is already facing a rush of orders for its fill that capacity rapidly, such is its current state of growth. company’s increased
R&D capability
current ceramics system. The latest customer to be announced is Having announced its second funding round (the previous round
BeamIT, Italy’s largest additive manufacturing centre. received funding from venture capital firm Catalyst CEL and (Above) 2019 will see
Additional orders also include a second installation for Autodesk), XJet has continued to grow its staff to 120 employees, the company launch
its high-resolution
Oerlikon, a leading 3D printing service provider based in and additionally declared the UK’s Carfulan Group as its first metals 3D printing,
Switzerland with facilities across Europe. global distribution partner. with soluble supports
To keep up with demand, XJet has announced that it has xjet3d.com and high density parts

DEVELOP3D.COM NOVEMBER 2018 7

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 NEWS
AMD GIVES FIRST GLIMPSE OF
MONSTER 64-CORE CPU
A
MD has given a first glimpse
of its next-generation EPYC
server CPU. Codenamed
‘Rome’, it features up to
64 cores and 128 threads,
double that of first-generation EPYC.
Powered by the ‘Zen 2’ processor core,
‘Rome’ uses 7nm process technology to
deliver what the company has claimed is
much higher performance and more CPU
cores at the same power.
It will be available for one- and two-
socket servers, giving a potential 128 cores
and 256 threads in total.
The new EPYC CPU should get the
attention of design and engineering firms,
because it promises to deliver incredible
performance in multi-threaded ray trace
rendering applications and simulation
tools, including the Computational Fluid
Dynamics (CFD) software, Ansys Fluent.
At the launch event in San Francisco,
AMD demonstrated the performance
gains that one can expect by putting a
single-socket ‘Rome’ system up against
competitive dual socket systems. The live
demonstration featured three servers:
one with a single ‘Rome’ processor with
New CRL event to celebrate women in product design
C
RL is running a new event
to celebrate the rich female
talent that exists within
the hardware sector, as
well as products developed
specifically for female customers, both
at CRL and throughout the industry.
‘Hardware for Women’ will shine a
spotlight on a number of inspirational
entrepreneurs. The theme of the event is
changemakers, so the focus will be on those
whose products have been developed to
tackle social problems.
8 NOVEMBER 2018 DEVELOP3D.COM
p07_08_09_10__D3D_NOV18-NEWS.indd 8
64 cores; one with two Intel Xeon 8180M
processors, each with 28 cores; and one
with two first generation AMD EPYC 7601
processors, each with 32 cores.
In the C-Ray ray tracing benchmark test,
the ‘Rome’ system was 9% quicker than
the Intel system and 2.5% quicker than
the AMD EPYC 7601 system, despite it only
using one CPU.
AMD executives were keen to point out
that the prototype ‘Rome’ system was air-
cooled, ran at standard clock speeds and
should deliver even better performance
when the CPU officially launches in 2019.
While the emphasis is on Rome’s
industry-leading 64 cores and number-
crunching capabilities, AMD told
DEVELOP3D that it would be releasing
several different models more suited to
workstation virtualisation, with fewer
cores and higher clock speeds for running
CAD and other 3D applications.
“Rome” is fundamentally a server
processor, but it is very likely that the
‘Zen 2’ technology on which it is based will
also trickle down to the desktop, perhaps
as Threadripper 3.
amd.com
Given that these products have been
created with women as the target audience,
and their development has been shaped
by women, the event will explore how
that informs product development, how
entrepreneurs have engaged with their
audience and the future of their products.
Speakers will include Chakshu Saharan,
founder and MD of Ignius; Nadiya Siddique
of UNA by Stealthy; and Solveiga Pakstaite
of Mimica. The event takes place at CRL’s
base near London on 29 November 2018.
centralresearchlaboratory.com
GE’s commercial
engines get green
light for 3D prints
I
n the near future, GE Aviation’s
GEnx-2B commercial airline engines,
which power the Boeing 747-8, will
feature an additively manufactured
bracket, now that the FAA has
approved a ‘change in design’ request.
The new parts will enter mass production
this month at GE Aviation’s facility in
Auburn, Alabama, and be produced using
GE Additive Concept Laser M2 cusing
Multilaser machines. The new brackets are
expected to take to the skies in early 2019.
Replacing a conventionally manufactured
power door opening system (PDOS) bracket,
the new part is used on the ground to
open and close the fan cowl doors to
enable access to the fan compartment for
maintenance.
ge.com/additive
Powered by the
‘Zen 2’ processor
core, ‘Rome’ will
deliver higher
performance and
more CPU cores at PostProcess
the same power,
says AMD launches in
Europe
P
ostProcess Technologies, a
provider of automated and
intelligent post-printing
solutions for industrial 3D
printing, has announced the
first step in its global expansion by
launching its full product line in Europe.
PostProcess solutions integrate software,
hardware and additive-formulated
chemistry to help with support material
removal and surface finishes of 3D-printed
parts. Its Connect3D software leverages
the CAD-file or 3D printer sliced file
to automatically define the necessary
requirements for post-printing, having
benchmarked over 500,000 parts, all built
with 3D printing technologies.
postprocess.com
09/11/2018 13:27
 SIEMENS PLM TO BET BIG ON
CONTINUOUS UPDATE FOR NX
W
hile it's not brand new
information, it was clear
from PLM Europe, the
European user event for
users of NX, Teamcenter
and other products, that Siemens PLM
is forging ahead with its plans to move
its flagship engineering application
NX to a continuous-release method of
software delivery.
Continuous release has become the de
facto standard for many types of software,
thanks to cloud computing, but the
engineering software industry has yet to
jump fully on board, Onshape and Fusion
360 aside.
From talking to the product management
team for NX, it's clear that they see a
great deal of benefit for the customer;
reducing the hassle and cost of moving
large numbers of users on a two or three-
yearly basis. They claim many customers
are now starting to request smaller, more
manageable and more frequent updates
to their engineering tools – and when you
consider who Siemens PLM’s customers
are (the rollcall includes Rolls Royce,
Daimler and so on), you know it's serious.
Other news out of PLM Europe is that
Siemens is forging ahead with its industry
p07_08_09_10__D3D_NOV18-NEWS.indd 9
ROUND
UP
Designed for companies
with limited or no access
to Catia V5 but still needing
to create or read NX data,
Theroem Solutions' new
CATIA V5i to NX CADverter
is a translation solution
designed to help solve
the issue of working with
and sharing incompatible
data formats
theorem.com
Following its beta
programme earlier this
year, Chaos Group has
launched VRAY for Unreal.
This allows users to use a
common set of applications
for both high-end, photo-
realistic visualisation and
virtual reality work to save
4.0, digital twin and digitalisation strategy, time and effort. It's out
which mimics similar moves from the likes now for £50 per month
of Dassault Systems and PTC (albeit with chaosgroup.com
different focuses). CEO Tony Hemmelgarm
detailed Siemens PLM’s progress so far
and while the company does not split out Ansys has teamed up
its numbers, its claims look interesting. with Granta Design to
PLM Europe always begins with a combine metal powder
welcome address from chairman of the bed simulation with
PLM Europe User Group, Martin Romers Granta's existing GRANTA
of ASML. This typically details areas of MI: Materials Gateway
interest for attendees and big areas of for ANSYS Workbench
focus for the event. Accordingly, the to build an integrated
slides included the buzzwords ‘Big Data’, set of workflows for AM
‘Industry 4.0’ and ‘IoT’, but also seemed to data capture, simulation
show that what really interests attendees and optimisation using
continues to be PLM and NX. validated materials data
FInally, the PLM Europe event itself is ansys.com | grantadesign.com
starting to change. The European and US
events have been run and managed (with
support from Siemens) by a user group Integration between
committee. But in the next few years, Autodesk’s Netfabb and
control will be passed to Siemens – in part Authentise’s additive
to cope with the community's expansion, workflow management
following Siemens' acquisition activities in tools looks set to allow
recent years. We hope these events don't Authentise users to load
lose their peer-based learning and sharing geometries directly into
benefits, for which they have become Netfabb with a single
legendary, as a result of this change. press of a button, using
siemens.com/plm | plm-europe.org Autodesk’s Forge platform
authentise.com
Kodak will supply new
3D printing systems
provider Evolve Additive
Solutions with imaging
systems, parts and
consumables based on the
Kodak Nexpress digital
PLM Europe is where electrophotographic
the continent's platform in anticipation of
engineering and the additive manufacturing
design community
technology’s commercial
gather to learn from
peers and find out release in 2020
what's coming from evolveadditive.com
Siemens PLM
DEVELOP3D.COM NOVEMBER 2018 9
09/11/2018 13:27
 NEWS

ALTAIR ACQUIRES SIMSOLID Rhino 6 for Mac

FOR MAINSTREAM SIMULATION is available for

A
ltair has announced that it beta test

is acquiring SimSolid,
an FEA start-up with
a meshes approach
that dramatically
shortens the set-up and solve time
for structural analysis.
If you’ve not come across SimSolid, we
spoke to its CEO Ken Welch some time ago,
and he explained the company's approach
rather neatly. SimSolid's tools represent “a
generalisation of classical FEA”, he said.
“While it uses the same variational
principals, the difference comes in how we
build approximation functions and associate
them with geometry. SimSolid doesn’t break
the system into finite elements. Instead it
discretises the original geometry in a more
abstract mathematical way.”
SimSolid uses high order functions built
on the fly during the solution phase, he
explained. Geometry is decoupled from
these functions, which allows the freedom
to use the most accurate functions possible.
“For example, when performing
thermal analysis SimSolid uses harmonic
polynomials which precisely meet the
thermal equation. Multiple solution passes
T
he long-awaited port of Rhino
6 to the Apple Mac platform is
now available for testing and
general merriment.
Those who follow Rhino will
know that the Rhino 6 release took a long
time to come to fruitition, but has since
been well recieved.
But what Mac users have been wondering
is when their chosen platform would get
the same treatment, with faster display, an
updated rendering system, Grasshopper
with multi-threaded components, a ray
Much of this work began with its SimScale's traced viewport display mode and so on. If
acquisition of Italian outfit Gestel and its approach makes it you're a current user, then the first work in
perfect for dealing
Evolve and Inspire tools, sold under the with complex
progress releases are now available.
solidThinking brand. These gave Altair a assemblies and rhino3d.com
set of tools that mixed together both 3D contact conditions -
design tools and simulation technology. as well as comoplex
The company then added in topology topologies like
lattices at various
optimisation and much more to the Inspire
and things got very interesting. In recent
scales
New Metals AM
months, it has also become clear that Altair
is reworking how it brings this set of tools tools for Magics
to market, with the solidThinking name
seemingly taking a back seat to the Altair 12 release

are performed and with each pass errors
are quantified and the functions are
adapted," said Welch.
“In contrast to other commercial FEA
products, adaptive analysis is not an
option. It is always active, even for large
assemblies.”
Commenting on the acquisition
specifically, Altair CEO James Scapa, said:
“We believe SimSolid is a revolutionary
technological breakthrough which will have
a profound impact for product design. It’s
incredibly fast, accurate, and robust and we
believe a game changer for our industry.”
Altair’s latest acquisition fits in with a
couple of other moves that it has made
lately. While the company's core business
is high-end simulation and analysis tools, it
has also been doing very interesting things
at the mainstream end of the market too as
it looks to address a wider audience.
Unlimited branding.
As many of the mainstream CAD and
simulation vendors look to bring topology
optimisation and lattice design into their
toolsets, Altair has a well-established set
of technology and proven products that
have been doing much of this work for a
decade or more.
altair.com
M
aterialise has launched
its simulation software
for metal 3D printing.
In combination with the
Materialise Magics 3D
Print Suite, this software will bring
simulation for additive manufacturing
(AM) to the production floor by
providing easy-to-manage simulation
capabilities at lower price points.
Available as a Materialise Magics module,
the new product aims to make simulation
easy to manage and accessible to a wider
audience. Users can apply simulation results
directly to the support generation and
orientation tools in their trusted Materialise
Magics environment. It supports fast re-runs
on a standard workstation without the need
for high-end processing power.
materialise.com

Surfcam 2019 responds to increase in hybrid manufacturing

R
esponding to the increase in
hybrid manufacturing, the
latest release of Surfcam has
introduced a new Additive
Machining module, in order
to provide support for direct energy
deposition methods.
Now offering a dedicated manufacturing
cycle, the software accurately guides a laser
over deposited powder material to form a
shape, from which the part can be machined
using Surfcam’s milling cycles to create the
final component.
As Surfcam 2019 R1 now offers Surfcam 2019
full ToolStore support for additive features a
dedicated additive
manufacturing, shapes can be built using
manufacturing
almost any milling cycle, including advanced module
functions such as rotary and 5-axis
simultaneous machining.
With nearly 30 new individual updates
to the software, the R1 release has also
introduced three performance-boosting
enhancements to its machining engine,
benefiting both turning and milling
operations.
surfcam.com

10 NOVEMBER 2018 DEVELOP3D.COM

p07_08_09_10__D3D_NOV18-NEWS.indd 10 09/11/2018 13:27

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 VISUAL DESIGN GUIDE
OLYMPUS DS-9500
DICTAPHONE
Accurate and mobile voice recording is still a key tool in the
legal and medical fields, among others, leading Olympus to
add wireless connectivity to its latest Dictaphone models

SECURE
STORAGE
The addition of Wi-Fi and file encryption
means that files can be shared without
manual docking, allowing important
information to be transcribed or acted
upon without delay, while still conforming
to strict data protection policies

SLIDE
SWITCH
The slide-switch is a classic design
that continues to be employed,
since it’s an intuitive way of
controlling recordings with a
simple push of the user’s thumb

CLEAR
CONTROLS
A simple array of physical buttons and
a large 2.4” colour display gives a clear
overview and makes it easy to find an
exact moment in a specific recording
MIC DROP TEST
Drop-tested from 1.5m, the DS-9500’s
housing is not only robust but also
stands up to more specific demands,
such as the use of alcohol wipes to
clean it after use on hospital wards

DOCKING
STATION
The docking station provides fast
charging, local file sharing via USB
and connection to a foot pedal
that lets the transcriber keep their
hands on the keyboard

12 NOVEMBER 2018 DEVELOP3D.COM

p12_13_D3D_NOV18_VDG_OlympusDictaphone.indd 12 06/11/2018 08:03

 GLOBAL DESIGN
The design and development of the DS series
was carried out at Olympus’ Tokyo design
centre, despite these products not being
for sale in Asian markets. The design team
therefore relied on research conducted by
their colleagues in Europe

RICH HERITAGE
Already famous for its cameras, Olympus
unveiled the world’s first microcassette
recorder in 1969, the Zuiko Pearlcorder. Its
portability and single-handed ease of use
instantly revolutionised the way that doctors,
lawyers, journalists and others worked

DUAL MIC
WITH NOISE
CANCELLING
A dual microphone system adds realistic
stereo recording, as well as new
background noise-cancelling technology
that allows it to focus on the user’s voice

PRICE &
AVAILABILITY
The Olympus DS-9500 Dictaphone
is available now and costs $599
olympus-europa.com

p12_13_D3D_NOV18_VDG_OlympusDictaphone.indd 13 06/11/2018 08:03

 DRIVING F
PROFILE

» At a technology centre located

in the UK’s Motorsport Valley,
work is underway on the world’s
first driverless electric race car.
Tanya Weaver  visits Banbury-
based Roborace to learn more
about autonomous racing and
the company’s plans to launch
a new competition in 2019
14 NOVEMBER 2018 DEVELOP3D.COM

p14_15_16_17_19_21_D3D_NOV18_CoverStory_Roborace-jlt.gc2 RB.indd 14 09/11/2018 12:05

G FORCE

The new DevBot 2.0 (top left), alongside the

orignal driverless Robocar (bottom right).DevBot
2.0 will ne used to develop the automated driving
system by using professional drivers to teach the
AI how to improve, as well as learning from the AI
how to better their own performance

DEVELOP3D.COM NOVEMBER 2018 15

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 T
here was something distinctly eerie
about watching the Robocar attempt
the notorious hill climb at this year’s
Goodwood Festival of Speed, an
annual motorsport event held in the
grounds of Goodwood House in West
Sussex, UK.
With no roar from the engine
and no driver sitting inside, this
futuristic, torpedo-shaped racing car stealthily ascended
the 1.16-mile course, using artificial intelligence (AI) to
navigate its path.
For some of those watching, both spectators lining
the course and audiences viewing via screens, it was a
challenge to accept the fact that they were witnessing the
first official autonomous ascent of the Goodwood Hillclimb
by a race car.
“At events like this and others where we put Robocar on
display, the first question everyone asks is whether it’s
remote controlled,” says Timo Völkl, technical director at
Roborace, a British technology company developing both
driverless and manually-controlled electric racing cars.
Producing over 500 horsepower from its four 135kW
electric motors and equipped with an array of radar and
LiDAR systems, ultrasonic sensors and machine vision
cameras, Robocar is very much in a self-driving class of
16 NOVEMBER 2018 DEVELOP3D.COM
p14_15_16_17_19_21_D3D_NOV18_CoverStory_Roborace-jlt.gc2 RB.indd 16
1
its own. As Rod Chong, Roborace’s deputy CEO, puts it, ●1 Hollywood
concept designer
“In our minds, Robocar is a robot that happens to have
and automotive
four tyres.” futurist Daniel Simon
Public scepticism is perhaps understandable. Despite is the brains behind
many car manufacturers claiming to be hard at work Robocar’s distinctive
design
on self-driving technology, we’re still not seeing fully
autonomous cars on our streets.
However, achieving what experts refer to as Level 5
autonomy is extremely complex. This is the most advanced
level of autonomy, where the only human input is turning
a car on and setting its destination in the sat-nav. From
that point on, the passenger sits back and enjoys the ride,
allowing the autonomous algorithm to take over and handle
all circumstances and environments in which the vehicle
finds itself.
“With all the talk of autonomous cars, everybody is
expecting to see them – but where are they?” says Völkl.
“Roborace can close the gap between what people think is
out there and what the technology actually can do, because
in the controlled environment of a racetrack, you can
showcase what people are really interested in – the state of
the technology at the moment.”
As Völkl suggests, racing has long been a proving ground
for new automotive technologies. Validated on repeated,
closed-course loops, emerging technologies are often
adapted for use in commercial vehicles. In the same way,
09/11/2018 12:05
 PROFILE

‘‘ In our
minds,
Roborace isn’t narrowly focused only on technology suited
to the racetrack. Instead, executives at the company describe the only stipulation being that it should be clear that there
it as an extreme motorsport and entertainment ‘platform’
Robocar for the future of road-relevant technology.
is a robot
that just IN-FLIGHT INSPIRATION
happens to The initial idea for Roborace was hatched in the skies –
literally. It was during a flight towards the end of 2015
have four that Denis Sverdlov, a Russian serial entrepreneur, and
tyres
’’ Alejandro Agag, a Spanish businessman and founder
of FIA Formula E, a motor racing championship for
electrically-powered vehicles, were discussing how to
incorporate AI into motor racing.
They wondered about a format in which each team
was provided with exactly the same standardised vehicle
hardware, with the differentiator being driver skill – but,
in this case, the ‘driver’ wouldn’t be human, but an AI
algorithm coded by each team.
By the time the plane landed, Sverdlov had already
decided upon the name of his next venture: Roborace,
an AI-powered racing competition and partner series to
Formula E. The aim was for Roborace to be an ambassador
for autonomous cars, so its first vehicle Robocar had to
communicate that intent in a knockout design. So who
better to bring on board as chief design officer than
Hollywood concept designer and automotive futurist,
Daniel Simon?
Simon was essentially given free reign on the design, with
was no human driver sitting inside.
Anyone who knows Simon’s work on films such as Tron:
Legacy, Oblivion and Prometheus (which he discussed as
a keynote speaker at our Develop3D Live event in 2014) will
appreciate Robocar’s distinctive sci-fi influence.
Simon wanted the car to look as though it was sucked
to the tarmac, achieved by angling the fenders down to
the fuselage. The fuselage itself is very low to the ground
and, by squeezing the majority of the technology inside its
torpedo-shaped body, including the battery package and AI,
the car has a very low centre of gravity.
Although Simon worked closely with Roborace’s
engineering team to ensure that his vision was possible,
in any product development process, there can always be
challenges when a design moves into engineering. But
in this instance, the chief challenge was that Sverdlov had
already really bought into Simon’s concept, to the extent
that exterior design could not be compromised by any
changes in the engineering stages.
Having received the final Autodesk Alias file from Simon,
the engineers brought it into Catia V5 and began work on
defining the Class A surfaces. Star CCM + was then used
for the computer fluid dynamic (CFD) calculation of these
Class A surfaces, which were correlated in the wind tunnel
with a 50% scale model.

2 3

●
2 Robocar and
DevBot in various
stages of build at
Roborace’s Banbury
facility
●
3 Daniel Simon’s key
aim with the design
of Robocar was to
communicate that no
human driver could
sit inside
●
4 Robocar has been
transported to a
number of events,
including this year’s
Goodwood Festival
of Speed

DEVELOP3D.COM NOVEMBER 2018 17

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 half_page_Q2_proveouts_DEV3d.pdf 1 24/10/2018 11:01:42

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 PROFILE

In the meantime, Roborace was developing some

components in-house, including the chassis, and working
LAYER BY LAYER
The hardware platform – powertrain, chassis and aero – ‘‘ It’s
complicated
with technology partners on the development of others, is only the first layer of the Robocar. There are a further
such as the battery, which is tailored specifically to the two; namely, the intelligence platform and the AI driving
to basically
Robocar. platform. fill a car
However, despite the design being radical in terms of The intelligence platform is the bank of sensors around with
showcasing what an autonomous car can look like without the car, as well as the car’s ‘brain’. This is provided by wattage
a driver, the engineering team were still constrained by NVIDIA Drive PX2, the chipmaker’s autonomous driving
the electric drivetrain. As Völkl says, energy is an inherent platform, which processes data from all the sensors to charge
problem of electric cars. (for more details, see box below, ‘Nvidia Drive motors it. It’s
“The energy is complicated. It’s complicated to basically onwards’). also more
fill a car with wattage to charge it and it’s also more complex The AI driving platform, meanwhile, is where
to save that energy and you’re also energy-limited, which machine learning algorithms analyse and respond to the
complex to
means it’s not easy to do long races, for example,” he says. environment around the car, activities that are conducted at save that
“So technology-wise, the design and the aerodynamics lightning speed. energy and
of Robocar are quite advanced, but in terms of an electric An essential part of bringing all this tech together lay in you’re also
drivetrain, it’s based on what was possible at that time.” teaching Robocar that it is, in fact, a car – and all that this
Most electric race cars, he adds, merely reflect what entails, says Völkl. “In motorsport, there is an alignment
energy-
combustion race cars can do, so tend to be very similar. It’s between a test driver and a performance data engineer, limited,
basically a question of taking out combustion and putting who analyse the car together. So most of the motorsport which
an electric drivetrain in its place. industry know where they can trust the driver and then add means it’s
But in future projects, he says, the Roborace team plans data on top,” he says.
to use its design and engineering skills to explore a very “When you take the driver away, you still have the data not easy
fundamental question: ‘How does an electric race car side, but for a lot of things, you don’t have the driver to do long
actually have to look?’ anymore. For example, if there is a mechanical failure on races
’’
5 6

●
5 DevBot being put
through its paces
with a human driver
inside, who then
gets out before the
machine takes over
●
6 An appearance
at the first Human +
Machine Challenge
in Berlin earlier
this year

NVIDIA The Nvidia Drive platform,

which consists of both
DRIVE software and hardware,
MOTORS was officially introduced
during the Computer
ONWARDS Electronics Show (CES) in
Las Vegas back in 2015. The
launch distinguished the
semiconductor company as
a key player in the future of
autonomous vehicles.
Just over a year later,
Roborace was one of the
first automotive companies
to publicly announce that
its autonomous, electric
racing car Robocar would
Nvidia
provides the
‘brain’ for
autonomous
vehicles
be equipped with an Nvidia
Drive PX2 ‘AI brain’.
This artificial intelligence
(AI) supercomputer
processes a huge volume of
data coming from Robocar’s
cameras and sensors, using
two of the world’s most
complex System-on-Chips,
along with two discrete
GPUs, to deliver up to
24 trillion deep-learning
operations per second
(TOPS). This is processing
power equivalent to 150
high-end laptops, delivered
in a case the size of a small
lunchbox.
“We have created an AI
system that we are able to
train to have superhuman
levels of perception and
performance that is used
for driving,” explains Danny
Shapiro, senior director of
automotive at Nvidia.
“We have taken what used
to be a data centre worth
of servers and shrunk it
down into a very small
form factor, designed to be
hidden inside a vehicle and
operate with great energy
efficiency.”
Many prototype
autonomous cars consume
thousands of watts of
energy, he points out.
“We’ve cut that down to a
few hundred watts. This is
especially important for
electric vehicles, because
you don’t want to shorten
the range of the vehicle.”
With Drive PX2, the
environment outside the
car is constantly scanned
and analysed with AI, while
algorithms compute how
to safely move the vehicle.
‘Safely’ is the key word
here, because it’s the safety
aspect that makes people
nervous and distrustful of
self-driving cars.
“Something that we have
introduced recently is a
simulation system to test
and validate a self-driving
platform. It’s called NVIDIA
DRIVE Constellation, and
enables users to simulate
different types of scenes,
including hazardous
situations, such as a car in
front running a red light or
a child rushing out in the
road after a toy. We can
drive millions if not billions
of miles in a simulator to
create a safe hardware and
software product before it
even hits the road,” Shapiro
explains.
Many companies are hard
at work on this technology.
In just under four years,
over 370 companies have
adopted Nvidia’s Drive
platform, including Daimler,
Toyota, Volvo, Volkswagen,
Audi, Continental and ZF.
“The industry has
underestimated the
complexity of developing
autonomous vehicles, which
is leading to the adoption of
even more computational
horsepower going into
vehicles. Now, the biggest
trend we’ll see over the next
several years is a movement
from R&D into production,”
Shapiro predicts.
Roborace is ahead of the
pack since both its cars –
Robocar and DevBot – are
already doing laps at high
speed. It has also upgraded
to the next-generation
DRIVE AGX Pegasus
platform. “Pegasus can
deliver 320 TOPS, ten times
that of the DRIVE PX2. So
we are able to process much
more data coming from
the sensors, which will of
course enable Roborace’s
cars to travel at higher
speeds, as information can
be processed faster,” says
Shapiro.
nvidia.com

DEVELOP3D.COM NOVEMBER 2018 19

p14_15_16_17_19_21_D3D_NOV18_CoverStory_Roborace-jlt.gc2 RB.indd 19 09/11/2018 12:05

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the car, a robot does not realise when it is driving with three
wheels. How can it? You need to teach it that it’s a failure
and it has to stop, otherwise it will just continue driving. So
you have to be sure that all these things that are normally
covered by the driver inside the car are now covered by AI.”
Manual vehicles are extremely complex products with
many team members collaborating and contributing their
individual skill sets throughout the development process.
So it’s obvious that adding autonomy introduces a whole
new level of complexity. As Völkl explains, “The single parts
of the car – whether software or hardware – are relatively
straightforward. A LiDAR is, of course, highly complicated
––, but it’s easy to understand what it does. The same
applies to other technology and components in the car, but
it’s about making sure that you have, at the end of the day,
a finished car that can also drive autonomously. So it’s the
sum of it which makes it so complex.”
TESTING TIMES
A lot of the teaching and programming of Robocar was
initially conducted in a simulation environment. When
it came to testing the AI software on a real-life race track,
Roborace built a development mule – DevBot – which has
the same sensors, motors, inverters and powertrain as
Robocar, just packaged slightly differently. Using a modified
Ginetta LMP3 race car tub, the most obvious difference is
that DevBot allows room for a driver, enabling the car to be
switched between manual and autonomous modes.
As the Roborace team progressed through the testing
stages, they decided upon a new format for Roborace’s
debut racing competition. Instead of pitting Robocars
against each other, as originally intended, with teams
competing solely on software, they would instead compete
in DevBots, with each team having both a human and an AI Alpha, will be released later this year.
driver. As Völkl says, think of it as two drivers sharing a car roborace.com
p14_15_16_17_19_21_D3D_NOV18_CoverStory_Roborace-jlt.gc2 RB.indd 21
PROFILE
in a race, except that one happens to be a machine.
As a proof of concept, the first Human + Machine ‘‘ The single
parts of
Challenge was carried out earlier this year on the Berlin
ePrix street circuit, with teams from the Technical the car are
University of Munich (TUM) and the University of Pisa relatively
competing against each other. As a time attack challenge, straight-
the human and machine each got three goes around the
2km track. The quickest lap was averaged and the team
forward,
with the fastest average was declared the winner – in this but it’s
case, TUM, with an average lap time of 91.59 seconds, four about
seconds faster than the University of Pisa. making
This challenge, in fact, offered a sight even more eerie
than that of Robocar on the Goodwood Hillclimb; that is,
sure that
the spectacle of a DevBot speeding along with no driver you have,
inside, but with its steering wheel still turning. at the end
of the day,
RACE TO THE FINISH
So where next for Roborace? In September 2018, CEO a finished
Lucas Di Grassi – a Brazilian racing driver and Formula car that
E champion – announced that Roborace’s debut racing can drive
season, Season Alpha, will launch in Spring 2019. The race
will feature identical cars, but teams can freely choose and
autonom-
develop their human and machine drivers. The competition
is open to OEMs, tech companies and universities.
ously
’’
The Season Alpha cars, based on the original DevBot car,
are currently in the build and testing phase. “The main
difference is that the new car is a two-wheel drive. The front
drivetrain is out and it’s a rear drivetrain, but the rest of the
basic concept is very similar,” explains Völkl.
Whereas the original DevBot was a rough-and-ready
prototype, this new car is getting the full Daniel Simon
treatment, as he is currently hard at work on designing the ●7 DevBot 2.0, the
new bodykit. The new car, as well as more details of Season new competition
vehicle which will
make its debut in
Spring 2019
DEVELOP3D.COM NOVEMBER 2018 21
09/11/2018 12:05
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DEFECT
FREE
VISION
» Heavy-duty industrial lighting manufacturer
Nordic Lights deploys computed tomography
to avoid expensive destructive testing and
eliminate critical measurement errors caused by
powder spraying for part preparation
N
ordic Lights, part of
the Herrmans Oy Ab
Group, is a Finnish
manufacturer of
premium, high-tech
work and driving lights
for heavy-duty vehicles
working in extreme
conditions. Its products are used in the
mining, construction, forestry, material
handling and agricultural industries.
The company has become an expert in
lighting technology through productive
collaboration with partners in different
branches of the industry. Continuous
strategic investments in R&D, laboratories
and the latest simulation software aims to
keep Nordic Lights a market leader.
The company’s R&D department plays a
pivotal role in the success of the company.
The developers and engineers working there
constantly strive to create new and innovative
world-class lighting solutions, working closely
with manufacturing teams to ensure that
only the strongest and most robust industrial
p23_24_D3D_NOV18_NikonNordic.indd 23
lighting products are produced. These
products are subject to rigorous testing and
rely on industry-leading inspection methods
for quality assurance.
THOROUGH TESTING PROCEDURE
Complete assemblies are typically made
from aluminium, steel, plastic and glass.
The components are manufactured through
a range of processes, including die-casting,
injection moulding and machining.
Before passing inspection, all new products
undergo extensive testing, for lumen
output and light distribution, vibration
and shock, dust and humidity, heat and
cold exposure, thermal cycling, thermal
protection, electromagnetic compatibility, full
functionality, abnormal conditions, chemical
resistance and usability.
For inspection purposes, Nordic Lights
previously relied on a white light system.
This had drawbacks: a lot of components
with ribs, pins and cylindrical holes are used
in production, and the white light system
typically had difficulty examining these.
PROFILE
1
Scanning components with narrow or tight
features can be incredibly difficult when
details are too deep for the light to detect.
As the white light system was only capable
of line-of-sight external surface inspection,
internal defects were neglected. To gain a
comprehensive picture of interiors, samples
and products were subject to expensive and
time-consuming destructive testing.
Another problem with this inspection
solution was that it required parts to be
painted and marked with alignment dots.
Painting or powder spraying was needed
as a part-preparation method for smooth
surfaces to avoid reflections in the white light
system. This, however, introduced critical
measurement errors on optical surfaces,
where precise tolerances are required. Not
only did this result in critical errors, but the
whole process was slow and time-consuming.
What was needed was a new measurement
solution, capable of analysing a variety of
materials and both internal and external
features with high precision and efficiency.
The team at Nordic Lights consulted with
DEVELOP3D.COM NOVEMBER 2018 23
06/11/2018 16:55
 3

1
2

various suppliers to determine

the best solution for its requirements.
Carl-Anton Manns, a test engineer at
Nordic Lights, took part in the search for the
new system to replace the white light system. 4
“The instrument needed to be able to analyse smooth
reflective surfaces with high precision. Being non-destructive
was also a big plus,” he explains.

ILLUMINATING THE BENEFITS OF CT

The Nikon XT H 225 ST with reflection and transmission
dual-target system has since been installed at Nordic
Lights, for R&D and troubleshooting requirements. It is
critical for all components to be approved before they can
be used in product assembly. The primary purpose of the
computed tomography (CT) system is to validate supplier
samples and new parts, as well as modified parts created
from new moulds.
A secondary purpose for the system is troubleshooting. 5
During the test phase, if failures are identified,
Previous page
complete assemblies can be scanned to identify the
●
1 The Sculptor from
Nordic Lights is a root cause without having to open up or destroy the hindrance. The new CT system addresses these issues and
driving light that product. For troubleshooting, CT has been used to now makes it possible to scan almost every component
combines headlight, search for air pockets or voids in the silicone glue before approval. It reveals internal defects, including air
indicator and parking
light in one unit between the aluminium housing and the lens, which pockets and voids, which was not possible with the white
could cause leakage. light system.
This page “Verifying the tool that makes the prototype part in the A further advantage the CT system has is that it can
●
2 The Scorpius Pro
beginning of the project saves a lot of trouble later on. With provide the precise results for dimensions and tolerances of
445 is a very durable
work light that Nikon CT, we can easily verify all dimensions and check optical parts, lenses, light guides and reflectors.
withstands shocks of for defects without needing to destroy samples. This is With its new, non-destructive inspection system,
60G and vibration of important to preserve the samples for other inspection Nordic Lights has experienced significant time savings,
15.3 grams
tests. There are also important savings in time and money especially during in the development phase. Defects can
●
3 Carl-Anton Manns
by avoiding sample preparation such as painting or be identified, traced and eliminated before parts proceed to
operates the Nikon
Metrology XT H 225 cutting,” Manns notes. production. For supplier-submitted samples, new parts or
ST, which is used to A major factor in the decision was the straightforward new moulds can be compared to CAD models before being
validate supplier
samples and new
maintenance of the open tube source. A system with an used in the assembly of complete products.
parts at Nordic Lights open tube source makes for lower maintenance costs and It’s worth noting that, right now, the system’s
●
4 The visual reports vitally, reduced downtime. Fast and competent service from transmission target isn’t used extensively by Nordic Lights,
detail wall thickness, Nikon support engineers was also a critical factor in the with the reflection target being the company’s primary
dimensional
decision-making process. tool for now. However, Carl-Anton Manns notes that the
inspection and void
analysis of the plastic transmission target will become useful in the near future,
light cover A COMPREHENSIVE UPGRADE as the high level of detail that can be achieved using it will
●
5 Dimensional The Nikon Metrology CT system represents a significant likely prove to be a significant advantage. In this way, the
inspection of a step up from the previous method used in the R&D system is not just providing an immediate solution, but
connector, including
areas with limited or department of Nordic Lights. The white light system new options for the future, too.
no line of sight offered limited repeatability and low speed, which was a nikonmetrology.com | nordiclights.com

24 NOVEMBER 2018 DEVELOP3D.COM

p23_24_D3D_NOV18_NikonNordic.indd 24 06/11/2018 16:55

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ELECTRO
MECHANICAL:
CHALLENGES
& SOLUTIONS
The rise of more sophisticated and more intelligent products
means efficient electromechanical design has never been more
key. We explore how Solid Edge addresses this new challenge
cross every industry, today’s
demanding customers expect more
A “intelligence” and functionality in
their products. Because of this, the
use of electronics in traditional mechanical
devices is increasing at an unprecedented
rate, and all of these electrical signals must be
physically connected throughout devices.
Alongside traditional electrical and
mechanical design and their inherent design
challenges, sensors are being added to
practically everything in an effort to connect
devices and create a “smart” world.
Signals from sensors are carried via wires to
embedded control boxes, actuated components
and antennas. Then, wires are bundled
into harnesses. As a whole, these electrical
distribution systems create the nervous system
of modern products.
The result is increasingly complex
KEY TRENDS IN ELECTROMECHANICAL DESIGN
INCREASING DESIGN COMPLEXITY:
Technological advancement, increasing safety
and environmental mandates, and escalating
consumer demand for advanced features and
functionality is placing tremendous stress on
both design and manufacturing processes.
This is having a detrimental effect on a
manufacturer’s bottom line.
II solidedge.siemens.com
Siemens Solid Edge + Electro - Mechanical 2018 - Rev1.indd 2
electromechanical systems, where electronics
and software control the mechanical aspects
of a design. Unfortunately, complexity is
rendering previously best practice processes
ineffective and ultimately obsolete , with
designers having a hard time keeping up with
the fast-changing demand.
The days of throwing designs over the wall
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physical prototypes to be built to see if the
product works as intended, are gone. Engineers
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Without a coordinated design flow, integration
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When electrical and mechanical engineers
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WIRING DESIGN
CHALLENGE: Without the proper contextual
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HARNESS DESIGN
CHALLENGE: Wire harness design is still a
time-consuming, error prone, manual process.
Without a coordinated design flow, integration
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PCB DESIGN
CHALLENGE: PCB designs, mechanical
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eliminate re-spins, get designs to market more
quickly and minimise costs.
MCAD-ECAD COLLABORATION
CHALLENGE: Electrical and mechanical
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When working in different environments, it
can be difficult to communicate, introducing
significant friction and errors in the process.
Siemens Solid Edge + Electro - Mechanical 2018 - Rev1.indd 3
SOLUTION: Integrated design processes
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eliminating the need to build a physical
prototype before producing the wire harness.
SOLUTION: Sharing 3D representations
allows visualisation of a design and detection
of potential problems earlier. This moves
validation of manufacturing and electrical data
earlier into the design cycle.
SOLUTION: Collaboration is recognised as
an enabler for increasing productivity. With
modern CAD tools and intelligent software,
users are able to synchronise data and
collaborate between domains.
Special Report: Solid Edge
BENEFITS: Solid Edge Wiring Design provides
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BENEFITS: Solid Edge Harness Design
automates many harness development tasks
including part selection, decomposition of
harnesses into buildable harnesses and the
creation of manufacturing reports.
BENEFITS: Solid Edge PCB Design speeds
development with communication of design
changes and automated review and approval
processes between the electronics and
mechanical domains.
BENEFITS: An efficient and effective ECAD-
MCAD collaborative process provides increased
productivity by enabling what-if scenarios and
allows engineers to co-design in their native
environments.
solidedge.siemens.com III
06/11/2018 17:00
 Special Report: Solid Edge
Sponsored by Siemens PLM Software

SOLID EDGE
A COMPLETE SOLUTION
While Solid Edge is a recognised technology leader in mechanical
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harnessing the strength of the Siemens PLM technology portfolio
Mechanical Design Electrical & PCB Simulation & Analysis

Solid Edge has been developed to provide
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modelling of intelligent parts and assemblies,
drawing creation and much more.
New tools for developing wiring, harness and
printed circuit board (PCB) components that
bring to bear experience and know-how of
Mentor Graphics (now part of Siemens PLM
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It’s one thing to create the 3D form of your
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 PROFILE

THE ART
OF GLASS
» Orora gets client buy-in on a new beer bottle design
using colour-matched, 3D-printed appearance models
with identical heft and hue to their glass counterparts

P
ackaging redesigns are serious Once printed, the bottles were put through
undertakings. On the marketing an in-house finishing protocol to bring them
side, changes are visual and to final product quality. This included wet and
emotional; on the manufacturing dry sanding, applying a surface tint and then a
side, they cost money. final clear coat to deliver a glass-like sheen. With
Before making the investment just a few simple steps, clear SLA prints were
to overhaul its glass bottle tooling systems, the transformed with impressive results.
maker of Australia’s James Boag’s Premium
Lager needed to be confident that an updated FAST FEEDBACK
bottle would not just represent change for The appearance models
change’s sake. Instead, the company needed to were ready within a
be sure that the new bottle would look good and week, allowing Orora
be well received by customers. Ideally, it wanted and Boag to quickly
confidence on these issues before spending put the new design
significant time and capital on the project. through customer
As the supplier of Boag’s bottles, Orora had a trials and gauge the
vested interest in validating the design quickly public’s reaction.
and accurately. Orora’s innovation and design They filled the
team started by contacting long-time partner, 3D 3D-printed
Systems’ On-Demand Manufacturing Services, bottles with
to assist in the development of a state of the art liquid, outfitted
3D-printed prototype. them with a label
With Boag’s existing supply chain processes in and cap and put
mind, a new-look bottle was designed to comply them in a shop
with the manufacturing infrastructure already for monitoring.
in place, in order to avoid expensive and time- Feedback from
consuming changes to that infrastructure. these in-store
trials indicated
3D PRINTING A GLASS LOOKALIKE that the new
To get Boag’s buy-in on the new design, a design was a hit,
credible-appearance model was needed for clearing the new
evaluation. The 3D-printed models needed to be design for production.
convincing and have the same clarity and hue “The new James
as glass, as well as the same in-hand heft. 3D Boag’s Lager bottle has set a standard within
Systems’ Manufacturing experts accounted for Orora for the way packaging design and 3D
weight disparities by adjusting the interior wall prototyping can come together seamlessly with
thickness of the design file based on the density short notice,” said a spokesperson for Orora’s
of the selected stereolithography (SLA) resin, and innovation and design team. “It’s the sort of
then got to work on colour-matching to achieve technology innovation that’s giving us a critical
the correct green used in the classic Boag bottle. edge when it comes to developing best-practice
Using 3D Systems’ SLA 3D printing technology bottling design and manufacturing solutions for
and VisiJet SL Clear resin, they printed four SLA our customers.”
prototypes. ororagroup.com | 3dsystems.com

DEVELOP3D.COM NOVEMBER 2018 29

p29_D3D_NOV18_ArtofGlass.indd 29 06/11/2018 17:04

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 PROFILE

SHAPING
A BETTER
BRACKET
» Intense heat and vibration in an engine compartment can easily cause part
failure. Kyungshin turned to topology optimisation to design stiffer, lighter
brackets to support their smart junction blocks and reduce risk, as Kim
Byeongwoo, the company’s Design Team Manager explains

A
smart junction block is the central
nervous system of an automobile. The 1
PCB of the junction box manages the
electricity and distributes power to all
parts of the vehicle, so it is a critical
component of the modern car. Because
of the vibration and high temperatures
in the engine compartment, the junction block and the
bracket that connects it to the chassis must be designed
with high stiffness to resist cracking and vibration fatigue.
Traditionally, the bracket was designed using a build-and-
test method, which was slow and costly. Also, engineers
tended to use more material than was necessary to ensure
high stiffness, which raised the cost of raw materials.
To avoid such over-design problems and develop plastic
junction block brackets with optimal dimensions to
maintain the necessary stiffness, Kyungshin engineers
used the topology optimisation functionality of Ansys
Mechanical to design durable, lightweight brackets.
With topology optimisation, the simulation software using topology optimisation.
automatically determines the best shape once engineers The bracket size was limited to the available space in
specify where supports and loads are located on a volume the engine compartment that would not interfere with
of material. For example, instead of a continuous solid any nearby component. Engineers defined the vibration
bracket, topology optimisation might find that a lightweight simulation conditions of the bracket by stipulating fixed
design with ribs and void spaces produces a bracket that points in the design and the acceleration load (4.5G)
meets all mechanical requirements. In this case, Ansys experienced due to vibration. They then used topology
Mechanical’s topology optimisation capability performed optimisation to generate an initial bracket layout using
digital exploration to determine the optimal bracket shape, density distribution analysis. They explored brackets
rib shape and rib positions. with density distributions of 20%, 50% and 80%, and
verified a bracket shape in each case that would provide
THREE STEPS TO SUCCESS the desired stiffness.
In the first step of the design process, Kyungshin The second step involved shape optimisation of the bracket
engineers defined the load conditions experienced by the based on the 50% density distribution model developed in
bracket in normal operation, established the allowable the first step. Kyungshin engineers generated a parametric
range of design parameters and generated an initial model with minimum and maximum dimensions for ●
1 Topology
design based on the density distribution of the bracket each defined design factor, including right and left side optimisation areas

DEVELOP3D.COM NOVEMBER 2018 31

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 PROFILE

bracket width, height, angle and centre radius. They then

performed design of experiments (DoE) simulations, 2
automatically employing the manual central composite
design (CCD) algorithm in Ansys OptiSLang to obtain an
optimal value for each parameter that resulted in a bracket
with reduced mass and increased stiffness compared to the
original bracket they were trying to replace.
Finally, the engineers verified the performance of
the proposed optimal bracket using vibration fatigue
simulation. The simulation involved varying the vibration
acceleration from 4.5G to 3.0G over three minutes while
the vibration frequency varied from 20–50Hz (at 4.5G) to
50–200Hz (at 3.0G).
The simulation also cycled the temperature from 90C to
–30C back to 90C over a 24-hour period to ensure that the
bracket could withstand the temperature variations inside
the engine compartment.

A BETTER BRACKET
The vibration fatigue simulations revealed that the 3
optimal model had a breakage lifetime of 2,259 operating
hours versus 1,544 hours for the original bracket model.
This is an increase in product lifetime of 46% – a
significant improvement.
The new bracket also was lighter, using 16% less plastic
than the original, continuous solid bracket. In the process,
Kyungshin engineers reduced the development period for
the new bracket from six months to three months, greatly
decreasing development costs.
They also created a new thermal-vibration-fatigue
simulation process using Ansys Mechanical running on
Ansys Workbench, in order to forecast the breakdown
of the junction block bracket, which can be used in
preventive maintenance scheduling.
By substituting simulation for traditional methods that
relied on an engineer’s experience and existing design
standards, Kyungshin engineers have cut in half the
number of bracket performance verification analyses,
from eight to four.
At a cost of approximately 50 million to 100 million
South Korean won (US$45,000 to $90,000) per verification
analysis, this is clearly a major saving.
4
In addition, they have produced a reusable model on
which to base all future junction block bracket designs.
The new model, employing Ansys topology optimisation,
offers a flexible design scheme, which the engineers at
Kyungshin will be able to modify for any other component
that they may decide to manufacture in the future.
Topology optimisation ensures cost savings through
designs that use the minimum amount of material
necessary to meet required mechanical standards while
increasing product lifetime.
ansys.com | kyungshin.co.kr

●
2 Definition of vibration
simulation conditions
●
3 Optimal model of bracket
based on optimal design value
●
4 Initial layout shape of
bracket rib
●
5 Result of density
distribution for Bracket 1
All images courtesy of
Kyungshin, Incheon, Korea

32 NOVEMBER 2018 DEVELOP3D.COM

p31_32_D3D_NOV18_Ansys_Kyungshin.indd 32 06/11/2018 17:30

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 PROFILE
WEARABLES
CHALLENGE
» Engineers at STMicroelectronics are using numerical
simulation to optimise semiconductors for use in a wide
range of devices, including health-related wearables
F
or specialists who design microdevices
such as actuators, controllers, drivers,
sensors and transmitters, growing
demand for miniaturised electronics
and Internet of Things (IoT) devices
is creating new challenges. From
responsive equipment and wearable
monitors to energy-efficient lighting
in the office and automation on the
factory floor, engineers need to bridge the gap between
their microscopic semiconductor components and our
macroscopic world with reliable and innovative products.
This is inspiring them to explore new ideas in the virtual
world of numerical simulation.
STMicroelectronics, a world leader in designing and
manufacturing semiconductor solutions, employs 7,500
individuals in the area of research and development (R&D).
According to Lucia Zullino, a technology R&D engineer at
the company: “In our field, we need to analyse very small
structures and understand their interaction with large
packages in different configurations over a wide range of
environments and applications.”
For semiconductor manufacturers like
STMicroelectronics, the choices that engineers make in
terms of materials and design are critical – and simulation
plays an important role in evaluating materials and
performance parameters.
“Much of our work is done through the Comsol
Multiphysics software, which we use to validate hypotheses
and to optimise products,” explains Zullino.
“There are about 30 users within STMicroelectronics, and
although we belong to different departments and work in
various locations, we are continually building and sharing
knowledge about mathematical modeling techniques used
in several projects.”
UNDERSTANDING INTERACTIONS
Simulation is used to understand multiphysics
interactions at every stage of the development process for
34 NOVEMBER 2018 DEVELOP3D.COM
p34_35_D3DNOV18_Comsolb.indd 34
several of the company’s products.
Examples include optimising an epitaxial reactor for
faster wafer production; controlling reactant flow distortion
in the wet etching process; and investigating the interaction
between die and package at the microscopic level.
In addition to design and manufacturing of microchips,
engineers at STMicroelectronics work on the design of
miniaturised actuators such as micromirrors used in
recognition technologies that require optics and cameras.
Simulation was also used in another actuator-related
project to investigate printheads and compare the
effectiveness of two different working principles:
displacement of ink through pressure-generated bubbles
or using a membrane actuated by a PZT, a ceramic material
made of lead zirconate titanate.
Through this work, the researchers were able to
determine that the thin-film piezo printhead offers better
compatibility with a wide variety of inks, higher printing
speeds, superior print output quality and extended
printhead lifetime.
In yet another development project at
STMicroelectronics, simulation was used to analyse the
properties of concrete and to predict the capacity of an
embedded sensor (figure 1) to monitor age-related changes
and relay a signal to the surface.
This structural health monitoring (SHM) system has
already been deployed in various locations in Italy. Here, it
is being used on various built structures, in order to assess
the health of the concrete from which they are constructed
and to log any damage that the structure incurs when it is
exposed to unexpected stress.
In this way, the SHM system enables engineers to
keep a close eye on structural integrity and reliability of
infrastructure.
WEARABLES FOR HEALTH
Over the years, STMicroelectronics has developed many
healthcare applications. In one prototype project, a patch
was designed to measure the bioimpedance of an organ,
07/11/2018 11:57
 We can assess materials and structures
‘‘
more quickly and screen for the best
ones, which means less time spent on
trials, better technical decisions and
quicker business decisions
’’

●1 Geometry of

1 2 the embedded
structural health
monitoring sensor,
with the sensing part
highlighted in blue
●
2 Technique used
to measure the
bioimpedance of an
organ
●
3 A 3D model created
from computed
tomography (CT)
images (left),
postprocessed
with CAD tools
(middle), and then
3 interpolated to
generate the volumes
(right) needed for
the analysis
●
4 Simulation results
showing the electric
voltage and current
distribution in a
human torso
4 5 Comparison
between measured
and simulated
bioimpedance values
(●5 ) for different
electrode shapes and
positions (● 6 )

such as the heart, inside the human body (as seen in
figure 2).
Working from medical imaging of human organs,
researchers created a 3D model (figure 3) to run an AC/
DC simulation in the frequency domain (figure 4) and
assess the effect of the electrode shape and position on the
measured physiological parameters.
The simulation results they obtained (figure 5) correlated
closely with real-life measurements and enabled the
development of a wearable configurable patch, capable of
indicating physiological changes.
These sensors will enable doctors and other healthcare
workers responsible for monitoring various heart
conditions to get real-time data to provide patients with the
best care, using the latest technology.
“Through simulation, we have learned a lot about
potential problems and we have gotten better at
optimising semiconductors for the outside world,”
says Zullino.
“Simulation now drives product design, both for internal
and external customers.”
She and her colleagues see many other opportunities
to use multiphysics simulation in other aspects of
development. For example, she says, studies on humidity
levels inside packaging and the potential for corrosion are
already in progress.
“We can assess materials and structures more quickly
and screen for the best ones, which means less time spent
on trials, better technical decisions and quicker business
decisions,” she says.
“Compared to physical testing, we can implement new
solutions and verify them at zero cost. Simulation is one of
the key tools that drives innovation.”
st.com | comsol.com

DEVELOP3D.COM NOVEMBER 2018 35

p34_35_D3DNOV18_Comsolb.indd 35 07/11/2018 11:57

 REVIEWS
SOFTWARE REVIEW
Luxion KeyShot 8.0
From its roots as a point-and-click renderer, KeyShot has grown in sophistication
and power in recent releases. Al Dean takes a look at KeyShot 8 to see if Luxion can
continue to expand its capabilities while still retaining its legendary ease of use
K
eyShot’s background is as a
system intended to provide
the quickest route between
your 3D design data and a
photorealistic rendered asset. While
in its first couple of years, the focus
was on the production of static images,
more recent releases have extended this
to cover not only animations (both as
movies or as 360-degree rotatables),
but also configurators for sales and
presentations.
At the same time, the system has
in recent releases started to gain
sophisticated tools for creating more
realistic, more complex and more
demanding material descriptions.
While the core geometry import tools
are there, many of these have been geared
towards solving those complex rendering
problems that might otherwise require a
more general-purpose rendering system
(such as 3dsmax or Maya, for example). So
shall we take a look at what’s new in this
release and see where KeyShot is today?
The good news is that the Keyshot user
interface remains much the same as in
previous releases. There’s just a few
tweaks here and there to make it more
usable. For example, there’s a new auto-
36 NOVEMBER 2018 DEVELOP3D.COM
p36_37_38_39_D3D_NOV18_KeyShot8.indd 36
» Product: KeyShot 8 save function that reminds you to save
» Supplier: Luxion your work – simple, but useful for when
you’re in your groove and might otherwise
Price: from $995
neglect this vital task. Other than that,
keyshot.com and some updates to the formats that
the system now supports (including the
addition of Rhino 6 and Inventor 2019
support), Keyshot looks pretty much how
you remember it.
MATERIALS UPDATES
That said, this release is a pretty big
milestone for Keyshot in terms of materials
support. While the last few major releases
introduced things like procedural materials
and the all-new material graph (itself
responsible for some added sophistication),
KeyShot 8 brings some important
background work to fruition.
Perhaps the biggest news is the addition
of a geometry shader. While we should
all be familiar with the ideal of a material
shader, which controls how the surface of
●1 The new Flakes an object looks, geometry shaders differ in
capability makes that they can create or modify underlying
the rendering of geometry. The difference is perhaps best
complex materials
explained by looking at the difference
(for example, filled
polymers) a snap once between the existing bump map tools and
you get your head the brand-new displacement map options.
around the workflow A bump map uses a greyscale image to
‘fake’ how a surface on an object, can vary
in height. While the effect is ok, it’s a fudge
that only really works with small variations
in height and doesn’t make any edits to the
underlying geometry.
A displacement map, on the other hand,
uses a map or other process to make
changes to the actual geometry, according
to requirements. If you take the example
of a car tyre tread, a bump map can sort
of replicate this, but the effect is a little
underwhelming. By using a displacement
map, along with the same texture map,
you can get a much better representation
of how the tread should look. In this case,
you are actually modifying the underlying
mesh, which means not only does the part
and texture look right, but also how it
interacts with light matches reality much
more closely.
What Luxion has done is start to
introduce geometry shaders into KeyShot
and the materials and effects you can
replicate are really interesting. While
displacement maps are pretty well
documented, for those times when you
want to add a specific set of deformations
to an object but don’t want to hard
model it, it’s ideal. This could apply to
adding texture or geometric features; for
09/11/2018 11:04
 2

example, think of the shape of a gravel the material (see figure 1 for a look at how Things get really interesting when you ●2 KeyShot 8.0’s

floor versus adding product detailing or
labelling.
BUBBLES & FLAKES
Geometry shaders can also be used to
construct more esoteric materials. For
KeyShot, the system gains both flakes and
bubbles as options. Bubbles are pretty
straight forward. Choose your material,
add in the geometry node in the material
graph, attach it to the geometry input of
a flake material is structured) and you can
add spherical voids to your material. You
have full control over the size (including
variation of size), distribution and density
of bubbles. This is most immediately useful
for liquids, but also consider building an
accurate glass bottle model; quite often,
you’ll see small bubbles in the glass. These
would be difficult to hard model in, but
with the geometry shader, the job becomes
pretty simple.
start to explore the flakes option. You have displacement map
tools indicate that
full control over the form of the flakes
Luxion is looking to
(either rectangular or spherical), size take advantage of its
(including variation) and density within new materials engine
a geometry body, as well as the material in coming releases.
that’s applied. While on its own, that Here, a structural
foam is replicated
doesn’t make much sense, there’s a wee
accurately, rather than
trick here: if you duplicate the body and using a texture and
apply your transparent material, you’ll opacity map
find that you can very quickly replicate
a wide range of polymer additives.

WORKFLOW: PHOTOREALISTIC SECTION VIEWS WITH KEYSHOT 8.0

●1 Import your model, as per usual. For this workflow, it’s ●2 Work through your usual texture and material assignment ●3 Sections are a material that’s applied to a part. KeyShot
useful to have meaningful parts names for each part, which workflow. Set-up your camera angles and anything else you allows you to add in primitives (in this case a cube) or you
don’t always come across from the CAD systems need to get a good image ready can model more complex requirements in CAD

●4 If you’re using KeyShot primitives, scale and move your ●

5 Grab the section material from the library and apply it ●
6 Last step is to adjust settings as well as selecting any
geometry into place. In this instance, we’re doing a quarter to your cube. You'll instantly see the section applied and components you want to exclude from the section. This will
section on a small electric DC motor capping faces rendered out save a bunch of time in post-processing such views

DEVELOP3D.COM NOVEMBER 2018 37

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 SOFTWARE REVIEW

SCATTERING MEDIUM the ability to import OpenVDB format files is now taken care of automatically, saving ●3 Similar to many

Moving on, another new material is
scattering medium. This allows you to define
materials that simulate particle scattering
such as smoke or fog and can prove useful
for adding in light effects, smoke and such.
It can also be adapted to quickly simulate
materials such as open core foams (as seen
in Figure 3).
It’s worth noting that while these can be
applied to a geometry shape, there’s also
to store particle simulations from other you the trouble. updates in KeyShot
8.0, image styles
systems. (Take a look at www.openvdb.org (available both in
for more information on this.) CUTAWAY SECTION VIEWS preview and post-
Elsewhere on the materials front, Lastly on the materials front is section render) allow you
there’s been work done to remove some material. Those of us who grew up to apply styling
additional workarounds relating to marvelling at bedroom-wall posters of and adjustments
to your image,
modelling and rendering the interface the Rolls Royce Merlin engine (guilty as without the need for
surfaces between hard parts and liquids. charged), or our parents’ trusty Haynes post-processing in
While previously you might have needed manuals, or physical models that allowed another app
to model in a gap or an interface layer, this you to view internal details know from

KEYSHOT VIEWER: MAKING ADVANCED VISUALISATION PORTABLE

Keyshot Viewer may not strictly be new for
Keyshot 8, having been introduced in the 7.0
release cycle, but it’s still very interesting.
Part of the attraction of a product like KeyShot is
the ability to generate marketing assets to be used
across a wide spectrum of company activities – for
example, in the sales and marketing department.
Being able to distribute that content in an
interactive manner is also increasingly useful. It’s
something that the automotive companies have
been doing for some time.
So what Luxion has come up with is a method
of wrapping up everything from a KeyShot
session (such as the model, variants in both
models and materials, and environments and
lighting) and making that portable dataset more
easily distributable. In this way, it can be sent to
whoever needs to have a more interactive view on
visualisation assets. That could be marketing folk
working with a photographer to finalise camera
angles for a shoot, for example, or sales folk
looking to demonstrate customisation options in
the showroom using a configurator running on a
touch-enabled machine.
It’s simply a matter of creating your dataset,
adding in your options and exporting the Viewer
file from Keyshot. Whoever needs to see it can
download the free viewer for PC or Mac.

38 NOVEMBER 2018 DEVELOP3D.COM

p36_37_38_39_D3D_NOV18_KeyShot8.indd 38 09/11/2018 11:04


 out and reapplied in other render projects
Keyshot has been through some pretty
interesting release cycles in the last few years
and the system has grown exponentially from
a relatively simple rendering system
for product designers to something much
more sophisticated
 years. These changes have seen the system
experience that a cutaway is a marvellous
way to show how a product operates,
particularly when cut surfaces are painted
just the right shade of red.
If you wanted to achieve this kind of
image previously, it typically involved
some manual modelling in your CAD
application and then importing the design.
Now, you can do it all in Keyshot.
You begin with the model you want
to section, and work through the usual
workflow, applying materials, lighting and
so on. Then, when you want to add in a
section, you add a piece of geometry that
represents the shape of the cutout.
In our example, we used a rectangular
block, created using KeyShot’s primitive
library. Then you apply the cutaway
material. This will hide the geometry of
anything crossing into that shape and
apply your cut-face conditions, which are
controlled in the material.
This first pass will cut through
everything in the model, but if you want
to then exclude certain items, you edit
the material property and add the parts
to your exclusion list. Compared to trying
to knife and fork this, it makes some
pretty complex renders a breeze – and
p36_37_38_39_D3D_NOV18_KeyShot8.indd 39
don’t forget, anything you do can also
be animated.
IMAGE STYLES
Moving away from materials definitions,
image styles are another headline update in
this release. As we’re all aware, rendering
systems are good at getting you 95% of
the way there, but in many cases, it’s that
last 5% that really nails the image for its
intended purposes.
This is where tweaks and other small
adjustments can really make an image really
sing and these changes are typically made in
Photoshop: adjustments to colour balance,
contrast/brightness, shadows, highlights,
curve adjustments and so on.
To help you eliminate the need for this
type of post-processing work, Luxion has
introduced image styles. Essentially, these
are the types of tweaks that are typically
a post-render activity, but they’re built
directly into KeyShot.
That means they can not only be applied
after a final image is rendered out, but
also during set-up and to the progressively
rendered image that you work with.
There is a whole host of post-processing
that can be applied and these can be saved
4
if you develop house styles. It’ll even
●4 KeyShot 8.0’s
cutaway materials
let you add in a front plate (such as logo
make section views in
3D a snap to build and,
or similar), to save you ever opening up when you play with
Photoshop again. the animation options,
interesting things
CONCLUSION start to happen
As we said at the start of this review,
KeyShot has been through some pretty
interesting release cycles over the last few
grow exponentially from being a relatively
simple rendering system for product
designers into something much more
sophisticated.
What’s interesting is that while
development work has managed to bring
some truly advanced rendering techniques
on board (with displacement maps,
scattering and much more), Luxion has
incorporated these enhancements without
ever losing the ease to use that has made
KeyShot so popular.
This is perhaps the best compliment I
can give the system as it stands today – it’s
as easy to use as it was when it was first
released.
All you need to do is load up a CAD
file (with reliable CAD translators), add
in some materials and render out your
image, to get results that are among the
best in the business.
At the same time, if you really want to
dive in, dial in your materials, build up
your 12-layered material graph flow chart,
tweak your HDRi environment to nail those
highlights and generate something truly
mind-blowing, then you can do that, too.
KeyShot has evolved to bring you all the
tools you need to create the remarkable
images that today’s products need and
consumers expect.
DEVELOP3D.COM NOVEMBER 2018 39
09/11/2018 11:04
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Siemens PLM Femap 12
Simulation is still a process that frequently requires a specialist set of tools.
Al Dean takes a look at one of the finest pre- and post-processing systems
on the market and discovers what makes Femap really sing
L
et’s talk about simulation: it’s
been an important part of many
engineering-led workflows
for decades now but, more
often than not, it’s still work that
is performed by specialists. Also,
despite the promises made by CAD
vendors over the years around the
great potential for CAD-integrated
simulation, it’s still not part of the
mainstream.
What this means is that, when you
set aside the focus on CAD-integrated
simulation, you’ll see there’s been a great
deal of work on continuing to develop rich
sets of tools for the more specialist end of
the market, and that these don’t always
get the attention they deserve.
These higher end, specialist tools
typically consist of solver technology,
alongside pre- and post-processing
systems. The solver technology provides
the computational engine to solve
problems, while pre/post-processing helps
with study set-up (for example, defining
a mesh, boundary conditions, load
constraints and so on) and subsequent
interpretation of results.
Siemens PLM’s pre/post-processor is
p41_42_43_D3D_NOV12_Femap12.indd 41
called Femap and has been on the market
for a good few years. It may have started
life as a graphical front end to Nastran,
but Femap has since grown to support not
just the various flavours of Nastran, but
also to connect to Ansys, Abaqus, LS-Dyna
and Marc.
USER EXPERIENCE
In terms of what to expect when opening
up Femap 12, the system has been through
something of a refresh in the last release
cycle. It’s now looking a lot cleaner and
more logically laid out.
In addition, work has been done on how
you interact with screen entities. There
have been improvements to graphics
processing, in order to take better
advantage of any GPU hardware present
(either AMD or NVIDIA-based). The addition
of the now-standard ‘view cube’ device
for manipulating your view, meanwhile,
enables quick inspection of parts.
The new graphics engine allows you
to switch on a ‘feature’ view that shows
either edges of CAD surfaces or curvature
changes, which will be really useful
when working with more complex CAD
geometry. And items like contour legends,
SOFTWARE REVIEW
» Product: Femap 12 view axes and such are all much more
» Supplier: customisable.
Siemens PLM It’s worth noting that these updates are
Price: from £233 on top of tools that have been in Femap for
per month many years. These include a wide range of
siemens.com/plm/femap tools for organising and abstracting your
CAD geometry and for building models
from scratch – things like groups and
layers will prove useful for many, as they
have done for years. So, shall we explore
how Femap works?
PRE-PROCESSING
The first goal of Femap is to allow you to
either build finite element models from
scratch or to import and repurpose CAD
files from a variety of formats. While in
some cases, this might be a simple case of
meshing, in many instances as you start to
explore more exotic forms of simulation,
it will involve abstracting away from
the raw geometry, This is to build more
appropriate or lightweight representations
of a part or assembly – whether that’s
●1 In Femap 12, you defeaturing models (such as removing
can now interactively
small features, fillets, chamfers and small
move and adjust
graphics screen parts) or constructing mid-plane or beam
entities including element models.
viewing axes While Femap boasts an impressive
DEVELOP3D.COM NOVEMBER 2018 41
09/11/2018 11:18
 SOFTWARE REVIEW

 these have been extended to work with

non-circular holes. That’s ideal for non-
●2 New feature and
silhouette lines aid
As a toolbox to allow you to get into the nitty- standard openings, whether for washers,
model visualization by
outlining model edges
gritty of both study set-up (which can involve a holes in 3D forms or items like gaskets.
Elsewhere, there’s been some interesting
and features

lot of idealisation and abstraction) and of results
interpretation and reporting, Femap is first class
 has a mesh ‘attached’ and either move,
range of mature and well-developed tools,
there’s always room for enhancement with
each release. In the Femap 12 release,
some key updates are worth exploring.
The first is that stitch has been worked on,
in order to combine surfaces into a single
body; this will prove useful for working
with those less than ideal models where
individual surfaces don’t connect well.
This now allows you to specify a maximum
tolerance and uses an iterative approach
to get surfaces stitched together without
too much hassle or manual rework.
There’s also been work done on Boolean
operations to do a better job retaining
combined curves and boundary surfaces,
which are typically used to reduce the
complexity of geometry to improve mesh
quality. There’s also a new ruled surface
option to allow building between curves,
with much more control over tangency
(either to connecting surfaces or a
specified vector). Again, this seems like a
small update, but if you’re trying repair a
complex model, then it’ll be godsend.
On the subject of defeaturing a model,
there’s also been some under-the-hood
work done on speeding up feature removal
– for example, to reduce the time spent
on removing a large number of small hole
features from minutes to seconds.
The last update we’ll cover for geometry
process is the new beam centreline
finder. While there’s good support in most
systems for building beam element models
from basic framework, this is a cut above
what’s typically offered and gives you
much more control. It’ll find your centre
lines, locate the most appropriate section
property from its own library (or prompt
for input where a match can’t be found),
then apply them across the model. It’ll
work as well in structures where each
solid has a unique section profile. If you’re
working with tubular structures, it’ll
handle the intersections as well.
MESH DESIGN
Moving on from geometry processing, a
key part of the pre-processing workflow is
the creation of the mesh. As you’d expect,
Femap already had a rich set of tools for
creating meshes for a variety of study
types and has done much to enhance that
existing functionality over the years. That
said, there’s still room for new tools and
redesigned workflows in the latest release.
One such example is the new washer and
pad meshing tools; these help you create
mapped meshes around holes and slots
to improve mesh quality, thus improving
overall model accuracy. While there
were existing tools to work with the most
common circular holes in the product,
work around reusing geometry and
meshes in a more efficient manner. Now,
if you grab a selection of geometry that
copy or mirror it, it’ll take both the
geometry and the mesh. If there are any
other items associated with that selection
(such as loads, constraints, connecting
regions), it’ll replicate those, too. The
same capability has also been introduced
for polar arrays. For those users who
like to keep a track of how entities are
numbered, these tools will also respect
any numbering conventions in place.
On the subject of numbering schemes,
work has also been done on how
numbering of entities is handled when
constructing models from separate mesh
files. It might be the case that you need
to split up work across a team or for pure
performance benefits, and then bring
those separate data files together. The
model merge command now affords you
full control over how numbering is handled
during your import and rebuild process, as
you bring disparate meshes together into a
single structure.
POST-PROCESSING
While we’ve covered most of the updates
to pre-processing, there’s also been a lot
of work done in recent releases on the
post-processing aspects of Femap, both at a
functionality level and how the system
connects to other solvers.
On the post-processing front, there’s
been work done across how you can

42 NOVEMBER 2018 DEVELOP3D.COM

p41_42_43_D3D_NOV12_Femap12.indd 42 09/11/2018 11:18


 display your results. For example, while
previous releases took a ‘one size fits
Femap is a all’ approach to colour ranges and their
fantastic bit application across a results set, you now
have much more control.
of kit for those Alongside this, dynamic criteria plotting
looking to allows you to select a criterion and vary
it to your chosen limits or values and
push their use immediately see how the model looks on
of simulation screen.
further and to You can use the ‘Generate From Criteria’
operation to group passing elements. Both
get into some of these make inspecting complex models
serious analysis much easier, letting you gain a quicker
understanding of your results.
work. Yes, it has Elsewhere on the post-processing front,
been tailored to Femap has been gaining more extensive
work perfectly charting tools in the last few releases,
outside of the typical X/Y plotting tools.
with Siemens The idea here is that rather than using an
PLM’s own another system (for example, Microsoft
Excel), you can do more work inside
Nastran code, Femap, keep it linked to your data and
but it’ll also keep things up to date, in a single place.
happily work Finally in post-processing functionality,
the system has at long last been given its
with some of the own automatic report generation tool. We
other leading all know the type of thing this entails: the
ability to set up your plots and charts and
structural codes have the system spit out a pretty generic
out there report. These things usually aren’t much
cop, but do a least give you a means to
 quickly generate all of your plots in one go.
Femap’s answer to this eschews the
typical HTML approach and instead
delivers report in Microsoft Word format,
saving another step along the way.
SOLVER CONNECTIONS
Alongside the functionality updates that
we’ve already discussed, work has also been
carried out on how Femap connects with
p41_42_43_D3D_NOV12_Femap12.indd 43
3
the various solvers out there. As you would
expect, its connectivity with Siemens PLM’s
●3 Topology
optimisation is
own NX Nastran solver is first class and, for reintroduced
expanding solution
this release, Femap also now supports the
recently introduced topology optimisation.
capabilities to
optimise design
The product has also been updated performance
to support a NX Nastran solution which
leverages technology from the Samcef
solver, which Siemens acquired when it
bought LMS. This is useful for simulation of
the delamination of composites.
And if you’re an Ansys house, Femap’s
connection to that system has been
completely reworked to support modern
element types, material definitions,
boundary conditions, and analysis options.
IN CONCLUSION
Femap is a fantastic bit of kit for those
looking to push their use of simulation that
bit further and to get into some serious
analysis work.
Yes, it has been tailored to work perfectly
with Siemens PLM’s own Nastran code, but
it’ll also happily work with some of the other
leading structural codes out there.
As a toolbox to allow you to get into the
nitty-gritty of both study set-up (which
can involve a lot of idealisation and
abstraction) and of results interpretation
and reporting, Femap is first class.
It’s also worth noting that, with its
maturing API set, Femap is also finding
a home in organisations that are looking
to automate their simulation use when
it comes to handling some routine or
repetitive tasks.
All in all, if you’re serious about
simulation and analysis, Femap 12 is
well worth investigating – so jump on
that trial and see what it can do for your
organisation.
DEVELOP3D.COM NOVEMBER 2018 43
09/11/2018 11:18
SSA cog 130mm x 190mm:Layout 1 8/5/18 17:12 Page 1

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 THE LAST WORD
The automotive design world is going
after electrification and autonomy hard,
but will these two paradigm shifts open
up the transportation industry to a
much wider audience? Al Dean takes
a look at how things might change
T
he automotive industry has
been on the cusp of a revolution
for quite some time now. As we
have started to see the sense in
moving away from the internal
combustion engine and our reliance on
fossil fuels, the electrification of cars is
one of a series of shifts that promises
to lead us to a brand new world of
autonomous driving. Yes, electrification
will happen first (led by governmental
legislation), but then we’ll gradually
increase levels of autonomy from
current capabilities to something truly
mind-bending.
Today’s vehicles are currently around the
Level 2 of autonomy; that’s partial assistance,

If you look at the earlier pioneers of electric
vehicles, they often made the mistake of too closely
matching what had gone before. Tesla is a prime
example – gull wing doors? Unless it’s a Mercedes
300 SL, then leave them on the Hot Wheels, Elon.

with LiDAR-based guidance in traffic and lane
assist tech in fancier cars. Once we start to
get to the higher levels, where the vehicle is
essentially doing all the work, things will get
really interesting, particularly from a design
and engineering perspective.
Even today, we are seeing new forms
and new explorations of what the future
of transportation looks like. The answer is
that it looks very little like anything that
has gone before. Take a look at Figure 2
on the right-hand side of this page. This is
an electric delivery vehicle from Banbury-
based Arrival (arrival.com). This isn’t your
average trannie van, is it?
Then you’ve got the SIN concept from
Danish bicycle manufacturer Biomega
(sin.biomega.com). Those familiar with
Biomega will know that the company
doesn’t scrimp on new details (its bicycles
are things of beauty), but developing an
electric vehicle is a bold move and one that
couldn’t have been conceived without the
use of an electric platform.
46 NOVEMBER 2018 DEVELOP3D.COM
p46_D3D_NOV18_LastWord.indd 46
Another curious one to pop up recently
is Cake (ridecake.com), a Swedish outfit
looking to bring its electric Kalk dirt bike 1
to market. It’s a slick-looking product, with
a top speed of 46mph, a range of 80km
or two hours of hammering it with a 15kW
power unit (around 20hp).
What I find so fascinating here is that
these are all companies that didn’t exist two
years ago. Yes, their teams all have design,
engineering and manufacturing experience
from previous places of work, but their core
market hasn’t been power transportation.
This is a serious shift in how transportation
devices are being developed.
And these companies are also
differentiating themselves with design.
2
Whether or not you like the Biomega
concept, with its almost child-like styling,
you have to admit that it’s bold (even if that
A-pillar is going to be an issue). The Arrival 3
van looks amazing and I’m first in the queue
for a consumer version when it become
available. Or I might save my pennies up for
one of Cake’s dirt bikes; again, the styling
here isn’t mimicking what’s gone before. The
company is basing its design on what works,
in terms of frame and geometry, but the rest
looks and feels new.
This I find endlessly fascinating. If you look
at the earlier pioneers of electric vehicles,
they often made the mistake of too closely
matching what had gone before. Tesla is a
prime example – gull wing doors? Unless it’s
a Mercedes 300 SL, then leave them on the ●1 Danish bicycle ●2 Banbury-based ●3 Electric motorcycle
Hot Wheels, Elon. design master Arrival is developing start-up Cake has
Biomega recently a 150-mile range developed a dirt
unveiled its SIN delivery vehicle. We bike without the
GET IN TOUCH: Email al@x3dmedia.com
concept, with a want to know when emissions and a
or on the twitter @alistardean — Al’s now 20kWh battery, the company plans lot more fun. The
off to look into a electric conversion kit for 80mph top speed to make camper styling is particularly
his aging Hyundai and 100-mile range conversions available interesting
09/11/2018 14:04
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