b'Engineer Innovation | Industrial Machinery & Heavy Equipmentadditional back-pressure. This all sums Velocity Mag. (m/s)15.0000 up to a digitally predicted improvement in massflow rate of more than 12.0000 22 percent. A number that according to HP engineers translates into 15 percent 9.0000 faster printing speed. And while the original duct development time was 6.0000 about 4 months, the new designs was achieved in four weeks of total 3.0000 development time, which is 75 percent of the one required for the baseline 0.0000 assembly. Unleashing the potential through Additive ManufacturingIn the old manufacturing world, the story would have stopped here -it Only withprobably would have never been told. Additive 22.3 % 14.8 % The design from the optimization Manufacturing process would have been labelled as mass flow printer headanother interesting but irrelevant increase speed increase exercise by some CAE engineers. Why? Because no one would have been willing or even able to bring this part to life with traditional manufacturing 10.2 % 75.0 % methods at a reasonable cost level. But not this time. Needless to say HP had all part costfaster the hardware in place to just print the reduction development new part, supported by Siemens software to preprocess the topology-optimized duct and nest it for the print job. And so, the new duct became reality just like the original non-and reaches a saturated highoptimized 3D printed design but with an performing state after around 80expected performance increase of more iterations, taking less than 8 hours onthan 20 percent. 100 CPUs. Will the Digital Twin keep the It is the flow itself that has become thepromise?new designer, just like a river definingBut then of course, that digital twin is its way. But in hours, not ages.still of no value if it does not represent reality. Skepticism was indeed high, The result is a shape with a ratherespecially among experienced flow organic appeal that would never haveengineers, when they first held the been considered by any traditionalunconventional part in their hands. So, engineering design procedure. So, theafter realization of the new duct, HP question to HP engineers was, can thisengineers took the part to the flow test unconventional design truly improve thebench. And the message was clear performance? As the CFD basedwhen they were measuring an increase comparison between the baseline ductin massflow rate of 20-23 percent and the newly topology optimized ductexactly like the digital twin predicted. indicated, the undesired swirl in theThis finding concluded the evolution of wake of the fan was indeed massivelya simple black plastic part into what reduced and the adjoint method found abecame famous as the mighty duct.way to direct the flow around the bend thereby minimizing secondary flowPutting computer aided engineering structures and streamlining the flowprocesses upside-downwithin the shortest possible distance.And while the story at hand takes place inside a printer head carriage assembly And all that without any flow- it could as well be taking place in a car, straightening auxiliaries causingan airplane, a chemical engineering 36'