Banca de DEFESA: ELISSON BORGES TESSARO

Uma banca de DEFESA de MESTRADO foi cadastrada pelo programa.
STUDENT : ELISSON BORGES TESSARO
DATE: 20/08/2025
TIME: 14:00
LOCAL: Online
TITLE:

GENERATIVE DESIGN AND FDM 3D PRINTING IN PLA: CRITICAL EVALUATION OF THE MECHANICAL RELIABILITY OF AN OPTIMIZED SUPPORT

KEY WORDS:

Generative design, Additive manufacture, Computacional simulation,
Structural optimization.

PAGES: 70
BIG AREA: Engenharias
AREA: Engenharia Química
SUMMARY:

This study investigates the application of generative design in the structural
optimization of supports manufactured by additive manufacturing, with a focus on the
correlation between simulation results obtained in computational environments and
experimental data derived from tensile tests. Initially, the material used in the
mechanical tests was characterized according to ASTM D638-22, resulting in an
elastic modulus of 3655 MPa and a maximum tensile strength of 28.843 MPa.
Subsequently, a finite element analysis was conducted using the data collected from
the tensile test, revealing a difference of less than 1% between simulation and
experimental results. Following this, a lifting bracket was designed using Fusion 360
as the generative design software, with constraints applied to the fixation location,
load-bearing point, and direction of applied forces. Multiple geometries were generated
for specific printing orientations, and the model with the lowest material consumption
was selected for fabrication. These models were then subjected to a specialized
mechanical test designed to simulate the actual loading conditions of the bracket, in
order to gather data and compare it with the computational simulations. The finite
element analysis applied to the model enabled the identification of critical stress zones,
whose locations coincided with the actual failure points observed in the physical tests.
Discrepancies in absolute stress values highlighted the influence of factors such as
anisotropy, interlayer adhesion failures, and typical imperfections in additive
manufacturing. The results demonstrate that, although generative design represents a
promising approach in the pursuit of lightweight and efficient solutions, its practical
application requires compatibility with the physical limitations of the additive process
and refinement of computational models. This work contributes to the understanding
of the interaction between automated design and the real behavior of materials,
offering a critical analysis of the mechanical reliability of solutions produced through
generative optimization.

COMMITTEE MEMBERS:
Presidente - DOUGLAS ALEXANDRE SIMON
Externo ao Programa - ADELANO ESPOSITO
Externo à Instituição - EDERVAL DE SOUZA LISBOA - UFSM
Externo à Instituição - WALTER J PAUCAR CASAS - UFRGS