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Transition to Net Zero Using Generative Design and Additive Manufacturing

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As our world transitions to renewable energy, making an unpredictable energy source reliable proves to be challenging. One solution to this problem is battery storage technology. However, scaling battery storage technology comes with its own challenges. Today’s lithium-based battery technology, while enabling higher energy density, is currently experiencing supply issues with shortages and high prices. Fortunately, sodium-ion technology might offer a cheaper and more abundant solution.

By quickly iterating at lab and pilot plant scale, at Exergy we have found solutions to some of these challenges for our clients. In a series of case studies, we show what has been achieved by combining the latest, most advanced generative design software with additive manufacturing and agile engineering.

This has helped our client prove their technology and quicken the time to scale up this game-changing technology. It has also unlocked future potential in other clients, as additional case studies highlight the power of combining advanced software and manufacturing technologies by light weighting, increasing performance, and improving efficiencies.

Specifically, the use of the Altair Sulis software enabled Exergy to create a lightweight, more efficient manifold, a more compact and more efficient heat exchanger, and explore new heat sink geometries that use biomimicry. As part of this presentation, illustrative Sulis workflows for the design of advanced lattice structures will be demonstrated. In particular, the breadth of options in terms of lattice types, and the flexibility with which lattice designs can be modified to suit end-user applications will be described in detail.

Learning Objectives:

  • Participants will broaden their understanding of how additive manufacturing technology and design for additive manufacturing software can greatly reduce the time to scale-up for emerging technologies in the energy sector.
  • Participants will receive a clear explanation of the advantages of different lattice geometries for a variety of engineering applications, showcasing the current capabilities of commercial DfAM
  • Participants will be exposed to the iterative design process that belies the design of lightweight manifolding and highly effective heat sinks that exploit biomimicry in their design.