Results-EXPERT CHALLENGE: What is the best configuration for this bracket?

We recently published a post asking metal Additive Manufacturing (AM) enthusiasts their opinion about three Part-Support configurations (A, B, or C) for the GE bracket and which configuration would show the least post-manufacturing deformation/warping upon Building-plate and Support removal.

We performed a metal AM process simulation via the Inherent Strain Method and concluded that the correct answer is configuration A, followed closely by C. The A configuration shows the least local deformations as well as the least overall global deformations.

We counted the answers from the poll of this post and concluded the following distribution in answers:

45% voted for A, 2% voted for B, and 42% voted for C, thus a majority guessed the correct answer and identified the Part-Support configuration A as the one showing the least deformation. (Note: the votes were counted on Dec/15/2023)

The figure below shows the exaggerated distortions (x10) of the simulated designs vs. their original, undeformed shapes:

Addressing the noteworthy comments made during the poll:

1. AM Process Efficiency and Build Height: Several comments highlighted the advantages of configuration A respective to the building height. This aspect is crucial in the planning of AM build processes. Opting for configurations with lower build heights serves to minimize manufacturing durations and subsequent costs. Hence, configuration A, aside from lesser warping, emerges as a promising candidate for enhancing process efficiency.
2. Utilization of Support Material: In this challenge, a conservative Support generation strategy was employed, yielding robust Support structures. However, there are ways to refine this strategy to reduce the Support volume.
3. Consideration of Heat Treatment: While heat treatment wasn't factored into this simulation, empirical evidence indicates that procedures like Hot Isostatic Pressing (HIP) can significantly alleviate residual stresses, thus diminishing overall deformations.
4. Accounting for Process Parameters: Our experience underscores the influence of intricate machine process parameters on the final outcome. While different process parameters are anticipated to induce localized and global changes in displacements, the overarching trends in displacements and warping are expected to remain the same.
5. The necessity of Experimental Validation: This study was performed via simulation only. Experiments of the different configurations are necessary to confirm the simulation results.

(Link to the bracket design: https://grabcad.com/library/ge-bracket-variant-1-1)