Giorgio De Pasquale

Daniela Barra

nTopology 4
User Guide
PART 1
2024

sss

A Comprehensive Reference Manual for

Beginners and Intermediate Users with
Step-by-Step Design-Based Approach

CASE STUDY: LIGHTWEIGHT AIRCRAFT WINGS

 Giorgio De Pasquale
Daniela Barra

nTopology 4
User Guide
PART 1
2024

A Comprehensive Reference Manual for

Beginners and Intermediate Users with
Step-by-Step Design-Based Approach

CASE STUDY: LIGHTWEIGHT AIRCRAFT WINGS

© 2023 Giorgio De Pasquale and Daniela Barra
All rights reserved
nTopology 4
User Guide
PART 1
6
Contents
Preface to the second edition - Unleashing the Power of nTopology Simulation ....................................... 9

PART 1........................................................................................................................................................... 11
1. General overview ..................................................................................................................................... 13
1.1. Create ................................................................................................................................................ 15
1.2. Modeling ........................................................................................................................................... 19
1.3. Lattices .............................................................................................................................................. 22
1.4. Fields.................................................................................................................................................. 28
1.5. Math .................................................................................................................................................. 31
1.6. Simulation ......................................................................................................................................... 38
1.7. Optimization ..................................................................................................................................... 44
1.8. Utilities .............................................................................................................................................. 47
1.9. Manufacturing................................................................................................................................... 50
1.10. Additive Manufacturing .................................................................................................................. 52
1.11. Architected Materials ..................................................................................................................... 54
1.12. Design Analysis................................................................................................................................ 55
1.13. Lightweighting................................................................................................................................. 63

PART 2........................................................................................................................................................... 89
2. Blocks ........................................................................................................................................................ 91
2.1. Solid base building ............................................................................................................................ 94
2.2. Boolean operations ........................................................................................................................... 96
2.3. Lists and groups............................................................................................................................... 111
2.4. Offset body ...................................................................................................................................... 112
3. Lattice ..................................................................................................................................................... 113
3.1. Periodic lattice generation ............................................................................................................. 114
3.2. Voronoi lattice generation.............................................................................................................. 123
3.3. Gyroid lattice generation ................................................................................................................ 126
3.4. Gradients ......................................................................................................................................... 130

PART 3......................................................................................................................................................... 133

4. Mesh ....................................................................................................................................................... 135
4.1. Surface mesh ................................................................................................................................... 136
4.2. Volume mesh .................................................................................................................................. 139
7
 4.3. Mesh cleaning ..................................................................................................................................140
4.4. Lattice mesh .....................................................................................................................................145
5. Finite elements analysis..........................................................................................................................151
5.1. Workflow analysis ...........................................................................................................................152
5.2. 1D beam elements ...........................................................................................................................158
5.3. 3D elements .....................................................................................................................................161
5.4. Homogenization...............................................................................................................................165
6. Import and export ...................................................................................................................................168
6.1. Export mesh files to Ansys...............................................................................................................172
6.2. Export of 1D reduced-order lattices ................................................................................................173
6.3. Export slices to 3D printer ...............................................................................................................175
7. Case study ...............................................................................................................................................176
7.1. Simulation of a lightweighted wing ................................................................................................176

8
Preface to the second edition
Unleashing the Power of nTopology Simulation

Dear Readers,

Welcome to the second edition of our comprehensive guide to nTopology

simulation software! In the dynamic landscape of engineering and design, where
innovation is the key to staying ahead, nTopology continues to stand at the
forefront. This edition builds upon the success of the first, offering a refreshed
perspective on harnessing the full potential of nTopology in the ever-evolving
world of additive manufacturing.

What's New?
Since the release of the first edition, the nTopology simulation software has not
only maintained its excellence in finite element methods (FEM) but has also
evolved to meet the demands of cutting-edge technologies. Cellular solids and
lattice structures have become central to advancements in materials science,
driven by the unprecedented capabilities of additive manufacturing. In this
edition, we delve deeper into these exciting developments and guide you through
the latest features that make nTopology a valid tool for forward-thinking users.
9
Why nTopology?
The allure of nTopology lies in its adaptability to the diverse needs of users with
varying levels of expertise in modeling and simulation. Whether you are a
beginner eager to navigate the software environment with ease or an
experienced user looking to push the boundaries of design, this guide is crafted
to cater to your unique requirements. The step-by-step procedures for simulation
implementation remain a cornerstone for beginners, ensuring rapid results and
a smooth learning curve. Meanwhile, seasoned users and design enthusiasts will
discover advanced insights to construct intricate models that showcase the true
potential of nTopology.

What Awaits You?

Our thematic chapters have been meticulously organized to offer a structured
learning experience. From foundational concepts to advanced techniques, each
section is designed to empower you with the knowledge needed to excel in your
projects. Direct links to the software environment facilitate a seamless transition
from theory to practical application, making the journey from novice to expert an
enjoyable and efficient one. At the end of the third part, we also show a real case
study about lightweighted aircraft wings.

As we embark on this journey together, we invite you to explore, experiment, and

elevate your skills with nTopology. The second edition of this manual is not just
an update; it's a gateway to unlocking the extraordinary possibilities that
nTopology brings to the world of simulation and design.

Thank you for choosing this guide as your companion in mastering nTopology
simulation software. Your journey starts here: let's create something
extraordinary!

Happy exploring!

Giorgio De Pasquale
Daniela Barra

10
PART 1

11
12
 1. General overview

1. General overview

Nomenclature
BLOCK head elements for creating and editing geometries
NOTEBOOK workflow made by Blocks
SECTION Blocks’ group made by the user

NTopology employs a hierarchical tree structure, where each level within the
tree is referred to as a "BLOCK." These Blocks encompass functions, geometries,
operations, results, and more. Notably, each Block is distinguished by its color,
with solid blocks adorned in green, mesh blocks in orange, and simulation blocks
in blue.
The NOTEBOOK, situated on the left side of the workspace, serves as the visual
representation for individual Blocks. Moreover, users have the flexibility to
designate a collective set of Blocks as a "SECTION."
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Figure 1

Command icons are shown at the top of the workplace. Each Block can also be
recalled by typing his name in the “Search blocks” bar of the Notebook (top left
side).

The icons are grouped in the following categories:

• Create;
• Modeling;
• Lattices;
• Fields;
• Math;
• Simulation;
• Optimization;
• Utilities;
• Manufacturing;
• Beta;
• Additive manufacturing;
• Architected materials;
• Design Analysis;
• Lightweighting;

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 1. General overview

1.1. Create

The section “Create” contains all the commands needed to create a model, such
as construction of bodies, points, vectors, curves…

The first command group is “Notebooks”.

ICON COMMAND NAME DESCRIPTION

A variable is an object, without a
VARIABLE
specific type class.

SCALAR LIST List of scalar values.

A group is created to group

GROUP
objects, even of different types.

CHOICE An item (type text) to choose in

SELECT BY CHOICE a list of possibilities.

It is shown an error or warning

VALIDATE
message defined by user.

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The second commands group is “Primitives”, with blocks for building base solids.

ICON COMMAND NAME DESCRIPTION

Creates a box by defining origin,
BOX
length, width and height.
Creates a cube by defining origin
CUBE and size (equal length, width and
height).
BOX FROM Creates a box by defining two
CORNERS corner points.
Creates a skewed box by
SKEWED BOX defining origin and vector with
directions x, y and z.
Creates a cylinder by defining
CYLINDER the two base center points and
base radius.
Creates a cylinder by defining
CYLINDER FROM
the height segment and base
LINE SEGMENT
radius.
Creates a sphere by defining
SPHERE
origin and radius.

Creates a cone by defining two

CONE
points and two radii.
Creates a toroid by center point,
TORUS normal direction, radius of the
hole and radius of the torus.
Creates a regular polygon by
REGULAR POLYGON number of edges and radius of
the circumscribed circle.
Creates a bounding box by
BOUNDING BOX
defining position of two points.

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 1. General overview

The next group of commands is “Vectors”.

ICON COMMAND NAME DESCRIPTION

POINT Object with x, y, z components.

POINT LIST List of points.

Vector object created from x, y, z

VECTOR
components.

Plane created from origin and

PLANE
directions x, y.

PLANE FROM Plane created from origin and

NORMAL normal direction.

Axis created by defining a point

AXIS
and direction vector.

Frame defined from origin and

FRAME
axes.

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The fourth command group is “Curves”, with blocks for defining lines and curves
(open and closed).

ICON COMMAND NAME DESCRIPTION

Object defined as a line between
LINE SEGMENT
two points.

CURVE FROM
Curve created by control points.
CONTROL POINTS

CURVE THROUGH Curve created by points (the

POINTS curve touches the points).
ARC, CIRCLES,
Objects generated by points
POLYGON FROM
defined as input.
POINTS

The last command is “Color”.

ICON COMMAND NAME DESCRIPTION

Selects a color, by defining R, G,
COLOR B value and A value
(transparency).

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 1. General overview

1.2. Modeling

In the section “Modeling” we found boolean operators and other operators

applicable to implicit body.

Figure 2

The first group of blocks are “Operations”, where there are blocks to modify the
profile (offset and extrude) and thickness or to create an implicit body from a
profile (loft, revolve, sweep and twisted profile).

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The second group of blocks is called “Booleans” and includes the operators of
union, subtraction, intersection, etc.

The third group collects the “Remap” blocks, which are used to allow to remap
an implicit body into a different space (cylindrical, spherical, etc.)

The following group “Evaluation” includes those blocks useful to make

assessments on the body mass, surface, volume, on distances, curvatures, etc.

20
 1. General overview

The last modeling’s group is “Utilities”, in which there are blocks for editing and
refining bodies, meshes, etc.

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1.3. Lattices

The “Lattices” section reports the commands for generation and modification of
lattice structures.

Figure 3

In the group “Lattice” we found the blocks usable to fill the body by tessellating
a Unit cell along coordinates defined (rectangular, cylindrical and spherical) or
along a Cell Map (Periodic Lattice).

In the group “Unit Cells”, we found the blocks usable to fill the body with a TPMS
lattice.
The blocks are divided in TPMS blocks, which generates the lattice without
thickness, Walled TPMS, which also include thickness imposed as an input and

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 1. General overview

Unit Cell blocks, which defines the unit cell for the lattice generation (unit cell
obtained by construction or by import).

The group “Cell Maps” includes blocks to build Cell Map within an Implicit Body
with different Cell Map starting point like min point or centroid point of the
body’s bounding box. The Cell Map can also be constructed starting from CAD
faces or meshes.

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The group “Conformal” includes block to build lattice starting from meshes (2D
or 3D meshes).

The group “Stochastic” includes blocks to build different lattice’s type including
volumes and surfaces based on stochastic method (stochastic point definition…).

The Stochastic blocks are: Voronoi Surface Lattice, Voronoi Volume Lattice,
Branched Lattice, Delaunay Lattice and Orthofoam Lattice.

24
 1. General overview

The last lattice group is called “Utilities” and includes the functions to modify the
lattice structure. These blocks are:

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ICON COMMAND NAME DESCRIPTION

Trim a cell map using an implicit
TRIM CELL MAP
body as trimming tool.

Trim a lattice using an implicit

TRIM LATTICE
body as trimming tool
Set a thickness (defined as
MODIFY LATTICE
block’s input) for lattice’s beams
THICKNESS
and faces.
Merges lattices together, by
MERGE LATTICES joining vertices with segments
below a defined threshold.
Creates ribs from lattice
EXTRUDE LATTICE structure; it is necessary to
define the field direction.
EXTEND OPEN Connects the open beams to the
LATTICE BEAMS rest of the lattice.
Removes vertices of lattice if
COLLAPSE VERTICES they are within input distance to
each other.
Create a Graph starting from line
GRAPH FROM LINE
segments, which became graph
SEGMENTS
beams
LATTICE FROM Create a lattice starting from
BEAMS beam list.
Create a lattice starting from a
LATTICE FROM
graph; it is necessary to define
GRAPH
the thickness.
FILTER BEAMS BY Remove beams of lattice that do
LENGTH not comply length condition.
Remove beams of lattice which
FILTER BEAMS BY do not comply angle condition; it
ANGLE is necessary t define the
reference angle plane
Select beams of lattice which
FILTER BEAMS BY
comply connectivity condition
CONNECTIVITY
(closed, open, floating).

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 1. General overview

ICON COMMAND NAME DESCRIPTION

FILTER BEAMS BY Remove beams of lattice
CONTAINMENT external to a region.
Remove beams of lattice which
FILTER BEAMS BY
do not comply thickness
THICKNESS
condition.
Remove beams of lattice which
FILTER BEAMS
do not comply a defined criteria.

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1.4. Fields

The section “Fields” groups the blocks for building and modification of gradients
and patterns (periodic or stochastic).

Figure 4

The first group is “Remap” and contains the blocks to modify the field among
cylindrical, spherical or scalar. The command is imposed by defining the
components of the new evaluation location.
We can use these blocks to modify the spatial distribution of the control points,
for example to build a solid.

28
 1. General overview

The next group is called “Periodic” and contains the blocks to define a periodic
pattern field, in particular Gyroid, Diamond, Schwarz, Lidinoid, SplitP and
Neovius. We use these blocks to define function’s size for lattices construction.

The “Noise” group contains the blocks called Simplex noise 3D and Cellular noise
3D. They are used to create noise function, by defining starting number of seeds
and frequency.

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The last group of this section is called “Utilities” and contains the blocks for the
modification and evaluation of the scalar field built with the previous blocks.

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 1. General overview

1.5. Math

The section “Math” contains the mathematical operators and functions

supporting the modeling operations.

Figure 5

The first group of Math section is “Operation”, where there are blocks for doing
operations, like addition, subtraction, multiplication, division pow, square root,
average and abs.

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The second group is “Trigonometry”, which contains blocks for trigonometric

functions.

The “Vector” group provides the blocks for operations on vectors.

32
 1. General overview

ICON COMMAND NAME DESCRIPTION

Returns the angle between two
ANGLE BETWEEN
input vectors; block’s inputs are
VECTORS
x, y, z coordinates.
Returns a perpendicular vector
PERPENDICULAR
to input vector; block’s inputs
VECTOR
are x, y, z vector coordinates.
VECTOR FIELD
Creates a vector field from x, y, z
FROM
scalar field.
COMPONENTS
Creates a vector field from a
VECTOR FIELD
scalar field, whose gradient
FROM GRADIENT
defines the new direction.
Calculates dot product between
DOT PRODUCT two vectors; block’s inputs are x,
y, z coordinates of two vectors.
Calculates cross product of two
CROSS PRODUCT vectors; block’s inputs are x, y, z
coordinates of two vectors.
Returns the angle between a
ANGLE RESPECT TO
vector and a plane, defined as
PLANE
inputs.

The group “Constants” contains blocks with constants’ values.

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The constants contained these blocks are:

• Euler’s number e = 2.7183
• Gravity acceleration g = 9806.65 mm/s2
• Golden ratio ϕ = 1.618
• Greek Pi π = 3.1416

The “Logic” group includes blocks for performing logical operations.

34
 1. General overview

ICON COMMAND NAME DESCRIPTION

Performs “AND” logical
AND operation; it returns a Boolean
value (true or false)

Inputs are Boolean values to be indicated by selecting the check marks. The
output is true if both checks are selected, otherwise output is false.

ICON COMMAND NAME DESCRIPTION

Performs “OR” logical operation;
OR it returns true if one or more
inputs are true.
Performs “XOR” logical
XOR operation; it returns true only if
inputs are different.
Performs “NOT” logical
NOT operation; it returns true if input
is false and vice versa.
Compares the input values; the
LESS THAN
inputs are scalar fields.

If the value of operand A (first input) is less than the value of operand B (second
input), the output is true. Otherwise, the output is false.

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ICON COMMAND NAME DESCRIPTION

Compares input values; if the
operand A (first input) is greater
GREATER THAN than operand B (second input),
output is true, false if otherwise.
Input values are scalar fields.
Compares input values; if the
operand A (first input) is less
LESS THAN OR than or equal to operand B
EQUAL TO (second input), output is true,
false if otherwise. Input values
are scalar fields.
Compares input values; if the
operand A (first input) is greater
GREATER THAN OR than or equal to operand B
EQUAL TO (second input), output is true,
false if otherwise. Input values
are scalar fields.
Compares input values; if the
operand A (first input) is not
equal to operand B (second
NOT EQUAL
input), output is true, false if
otherwise. Input values are
scalar fields.
Compares input values; if the
operand A (first input) is equal to
EQUALS operand B (second input),
output is true, false if otherwise.
Input values are scalar fields.

36
 1. General overview

The last group of Math section is “Utilities”, where there are blocks like linear
map, clamp, compare, ramp, mix, random sequence, ceiling, floor and round.

The Round block rounds up or down the input value to the smallest increment
of input’s interval.

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1.6. Simulation

The “Simulation” section contains the blocks needed for running a simulation,
from materials definition to export of results.

Figure 6

The first group is “Analysis” where we can select the type of simulation among
static, modal, buckling and thermal analysis.

38
 1. General overview

For the static analysis block, for example, the input needed are the model to
study and the boundary conditions. The inputs will be explained in detail in
Chapter 5.

The block called “Homogenize Unit Cell” simplifies a periodic structure by

performing numerical homogenization. The inputs needed are the unit cell of
model, the design volume to be homogenized and the tolerance for
simplification.

If the Mechanical and Thermal option are checked, the block calculate also
elastic properties and thermal properties from the unit cell model.

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The second group of this section is “Model” and contains fundamental blocks for
building simulation workflow (see Chapter 5)
• FE Model
• FE Component
• FE Lattice component
and blocks for defining surfaces, edges and bodies on which to apply boundary
conditions
• Tie constraint
• Structural bonded contact
• Thermal bonded contact

The “Material Attributes” group includes the blocks to define simulation’s

materials; it is possible to define isotropic or orthotropic material.

40
 1. General overview

The group “Mesh” includes the blocks to define surface or volume mesh, which
is needed for the FEM analysis. For greater precision it is necessary to refine and
clean meshes.

“Boundary conditions” group includes all types of load, like force (edge, surface),
pressure, acceleration load, point moment, temperature load or heat
generation.

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The “Utilities” group hosts the blocks for selecting boundary entities in a FE
mesh.

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 1. General overview

The group “Exchange” includes the blocks for importing or exporting analysis
results. Here we can, for example, import FE mesh, boundary conditions or
results; it is also possible to export point maps of displacement obtained from
the simulations.

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1.7. Optimization
The “Topology Optimization” section contains blocks for shape and topology
evolution with optimization target functions.

Figure 7

The first group is “Optimization”. It performs topology optimization on a FE

model or on a solid body given as input. Before to run the optimization setup,
we need to define the material, the maximum number of iterations to consider
and constraints.

The second group is “Responses”, which contains the blocks to assign the target
function of the optimization in terms of the maximum value of one selected
“response” in optimized geometry. The “response” can be volume, structural
compliance, stress, displacement or natural frequency.

44
 1. General overview

The “Constraints” blocks group defines the constraints for topology optimization
process. They can be a volume, a stress,a displacement, planar symmetry, a FE
region, overhang or a geometric extrusion built from a curve.

Blocks in the group “Post-processing” are needed after the topology

optimization process.

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ICON COMMAND NAME DESCRIPTION

Create an implicit body from a
IMPLICIT BODY
specific iteration of optimization
FROM TOPOLOGY
process; the iteration desired is
OPTIMIZATION
an input.
CONSTRUCT Creates an implicit body from
OPTIMIZED BODY optimization results.
Creates a scalar field based on
OPTIMIZED DENSITY
min and max thickness values of
THICKNESS
input elements (derived from
MODIFIER
topology optimization).

The last three blocks in the group “Exhange” are the following:

ICON COMMAND NAME DESCRIPTION

Import topology
IMPORT TOPOLOGY
optimization results from
OPTIMIZATION RESULT
a path.
Export optimization
EXPORT TOPOLOGY
convergence history in
OPTIMIZATION HISTORY
.csv or .txt format.
Creates a scalar point
TOPOLOGY OPTIMIZATION map based on
DENSITY POINT MAP optimization element
densities.

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 1. General overview

1.8. Utilities

The section “Utilities” contains various tools for supporting the modeling.

Figure 8

The first group is “Exchange”, and includes the blocks for importing or exporting
parts, CAD, lattices, meshes, points, etc.

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The blocks in the “Conversion” group support the conversion from different
types of input, for example:
• From mesh to CAD body
• From mesh to Implicit body
• From CAD body to mesh
• From implicit body to mesh
• From mesh to voxel grid

The “General” group hosts the blocks to perform the operations contained in the
list, by removing, inserting or filtering one or more items from the list.

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 1. General overview

Last subgroup is “Transform” in which there are blocks that apply operations of
scale, rotation, translation, etc.

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1.9. Manufacturing

In the section “Manufacturing” there are blocks for the subdivision of bodies and
parts into layers (specific for additive manufacturing).

Figure 9

The “Slicing” group includes the blocks for preparing printing processes. For
example, “Slice body” divides input body in slices, with input height of each layer.

50
 1. General overview

The blocks of “Exchange” group allow exporting the slices to different formats
and to printing format directly (e.g. Renishaw or EOS).

In “Utilities” group, there are three blocks:

• Manufacturing support volume: it find support volume needed for
correctly print.
• Bounding box 2D nesting.
• Minimum Support Orientations: it find the best orientation to reduce
support regions.

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1.10. Additive Manufacturing

In the “Additive Manufacturing” section, there are blocks for preparing the print,
supporting the export to formats that can be red directly by machines from EOS,
Renishaw, etc.

The first group is called “Material reduction”.

ICON COMMAND NAME DESCRIPTION

Creates a shell of an implicit
body (defined as input) and it
SHELL WITH
reinforces the regions near input
REINFORCEMENT
(CAD faces) with a defined
thickness (reinforce thickness).
PERFORATE FROM Creates an hole in position
CAD FACE defined by CAD (input).

INFILL VOLUME Generates a lattice structure

LATTICE internally to a reference volume

Generates a gyroid structures

INFILL GYROID
internally to a reference volume

MERGE SHELL AND Merge a body with a shell with

INFILL blend radius, defined as input.

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 1. General overview

In “Build Preparation” group, there are blocks for simulate the position of body
in the build plane (for example, blocks for translate, orient or slice the parte
before printing).

The blocks of “Build Volumes” group create bounding boxes with specific
dimensions of the printing planes. The printers included in the nTopology library
are EOS, Renishaw and RenAM.

In the “Export” group, finally, there are blocks for exporting slices. Some blocks
are present in different groups, like the exporting blocks also present in the
“Manufacturing” section.

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1.11. Architected Materials

In the “Architected Materials” section, we find the blocks for cleaning operations
on lattice, as removal of open beams.

In the “Latticing” group, there are the blocks useful for the creation of lattices,
also present in the “Lattices” section.

Other groups include the “Texturing”, for lattice pattern control and “Utilities”.

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 1. General overview

1.12. Design Analysis

The blocks contained in the “Design Analysis” section can be used to impose the
pre-analysis model and to select the materials from the software library.

Figure 10

The group “Sample Materials” allows the selection of material blocks from the
nTopology library.

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The materials available in the nTopology library are:

• Al 6061-T6
• Al 7050-T7451
• Al 7075-T6
• Al-Si-10Mg
• Inconel 625
• Inconel 718
• Ti-6Al-4V
• Stainless Steel 316

In “Mesh Generation”, there are blocks to generate the FE mesh, that is needed
for the simulation workflow.

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 1. General overview

In “Model Assembly”, we find the blocks for generating the FE model. The choice
of the correct block depends on the body type considered (solid or lattice body).

ICON COMMAND NAME DESCRIPTION

Creates a model for solid bodies.
Inputs are FE mesh, materials
FE SOLID MODEL
type and materials frame
(material coordinate systems).
Creates a FE component for solid
bodies. Inputs are solid mesh,
materials type and materials
FE SOLID frame. It is necessary to create a
COMPONENT block for each body’s
component and combine them
later (with the “FE Model”
block).
Same function of “FE Solid
Component” block, but with
FE LATTICE lattice. Inputs are lattice mesh
COMPONENT calculated on a simplified beam
structure, beams thickness and
materials type.
Creates connectors between
body components, in particular
FE LATTICE between solid and lattice mesh.
CONNECTOR Inputs are FE lattice mesh, FE
solid mesh, implicit body infilled
by lattice and tolerance.

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In the “Selection Sets” group, there are blocks to define the body’s regions
(faces, nodes, etc.) where boundary conditions can be applied. The selected
regions are called “FE Boundary”.

ICON COMMAND NAME DESCRIPTION

Creates a FE boundary based on
mesh; inputs are mesh, entities
to select (nodes, edges or faces)
and tolerance. With the Reverse
FE FACE BOUNDARY option, we can select the entities
outside the input body.
Otherwise, the block
automatically returns the
entities inside the body.
Creates a FE boundary based on
CAD body; inputs are CAD body,
FE CAD REGION
mesh, entities to select (nodes,
edges or faces) and tolerances.
Creates a FE boundary based on
mesh and flood fill operation.
Inputs are mesh, type of entity,
origin, angle and direction.
Blocks return elements closest
FE BOUNDARY BY to the origin, following the
FLOOD FILL defined direction (input). The
angle gives the range of
selection for elements: large
angles give an output with
several elements; small angles
give narrow range of values.

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 1. General overview

In the “Restraints” group, there are blocks to define constraints or restraint

conditions.

ICON COMMAND NAME DESCRIPTION

Creates a fixed displacement on
CAD face defined as input; other
FE FIXED FACES
inputs are FE mesh and
tolerances.
Defines a displacement restraint
on FE Boundary. It is possible to
DISPLACEMENT
control translational and
RESTRAINT
rotational restraints in directions
x, y and z.
TEMPERATURE Applies a temperature constraint
RESTRAINT to the FE Boundary (input).

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In “Loads”, there are blocks to apply the static and kinematic actuation to the
model, including forces, moments, pressures, accelerations, etc.

ICON COMMAND NAME DESCRIPTION

Applies a force to the FE
FORCE
boundary point defined as input.

Applies a force to the FE

SURFACE FORCE
boundary area defined as input.

Applies a pressure to the FE

PRESSURE
boundary area defined as input.
Applies a force to FE boundary
defined as input; inputs are load
POINT FORCE
application point, FE boundary,
vector force and frame.
Applies a point moment to FE
boundary defined as input;
POINT MOMENT
inputs are load application point,
FE boundary, moment and frame
ACCELERATION Applies an acceleration load to
LOAD FE boundary defined as input.
Applies a heat flux to FE
SURFACE HEAT boundary defined as input. The
FLUX flux is applied orthogonally to
the boundary faces.
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 1. General overview

In the group “Analysis”, we can select the type of simulation among static,
modal, buckling and thermal analysis.

ICON COMMAND NAME DESCRIPTION

STATIC ANALYSIS Selects the static analysis type.

MODAL ANALYSIS Selects the modal analysis type.

Selects the buckling analysis

BUCKLING ANALYSIS
type.

Selects the thermal analysis

THERMAL ANALYSIS
type.

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In “Fields”, we can find some Blocks that are generated during the analysis.

The last subgroup, “Export”, contains blocks useful to export the FE mesh, the FE
model and the analyses setup to several different CAE formats (Abaqus, Ansys,
Patran, etc.)

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 1. General overview

1.13. Lightweighting

The blocks grouped in the “Lightweighting” section provide the operations of

lattice morphing and shape manipulation.

Figure 11

The group “Volumetric” contains blocks to infill solid body with lattice.

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ICON COMMAND NAME DESCRIPTION

Creates a Delaunay lattice by
INFILL DELAUNAY defining vertex spacing, number
LATTICE of random seed and beam
thickness.

Figure 12

ICON COMMAND NAME DESCRIPTION

Infills a solid body with gyroid
INFILL GYROID lattice; inputs are the solid body
to infill, cell size and thickness.

Figure 13

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 1. General overview

Figure 14

Figure 15

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ICON COMMAND NAME DESCRIPTION

INFILL LATTICE Creates a lattice between two
BETWEEN FACES CAD surfaces.

Figure 16

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 1. General overview

Figure 17

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ICON COMMAND NAME DESCRIPTION

Infills a solid body with lattice.
Several lattices are available in
INFILL VOLUME the library (see below list).
LATTICE Inputs are solid body to infill,
lattice type, cell size, rotation
and thickness.

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 1. General overview

Figure 18

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Figure 19

ICON COMMAND NAME DESCRIPTION

Creates a tetrahedral lattice
INFILL TET LATTICE from solid body; inputs are solid
body and beam dimensions.

Figure 20

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 1. General overview

Figure 21

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ICON COMMAND NAME DESCRIPTION

Infills a solid body with Voronoi
INFILL VORONOI
lattice, by defining point spacing
LATTICE
and thickness.

Figure 22

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 1. General overview

The group “Surface” contains blocks to generate lattice structures from the cell
count parameters (U and V) inside the input body.

ICON COMMAND NAME DESCRIPTION

CONFORMAL FOAM Infills the solid body with
LATTICE conformal foam lattice.

Figure 23

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ICON COMMAND NAME DESCRIPTION

HONEYCOMB Infills the solid body with
RIBBING honeycomb lattice.

Figure 24

ICON COMMAND NAME DESCRIPTION

STRUCTURAL Infills the solid body with
RIBBING structural lattice.

Figure 25

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 1. General overview

ICON COMMAND NAME DESCRIPTION

VORONOI
Infills the solid body with
STRUCTURAL
Voronoi lattice.
RIBBING

Figure 26

ICON COMMAND NAME DESCRIPTION

Generates holes with imposed
PERFORATE BODY
size in a solid body.

Figure 27

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In the “Shelling” group, we find the blocks to create a shell from an implicit body,
by defining the thickness.

ICON COMMAND NAME DESCRIPTION

Generates a shell from input
solid body. The thickness is
SHELL
added along the input direction
(inward, outward or center).

Case of “inward direction”:

Figure 28

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 1. General overview

Case of “outward direction”:

Figure 29

Case of “center direction”:

Figure 30

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ICON COMMAND NAME DESCRIPTION

Generates a shell starting from
inside the body. The input is a
VARIABLE SHELL
negative distance that defines
shell thickness.

Figure 31

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 1. General overview

ICON COMMAND NAME DESCRIPTION

Generates a shell from solid
SHELL WITH
body and adds a reinforcement
REINFORCEMENT
zone near selected faces (input).

solid body

selected face

reinforcement

Figure 32

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ICON COMMAND NAME DESCRIPTION

Merges a shell and a solid body
with a blend radius. Inputs are
MERGE SHELL AND shell the body to merge and infill
INFILL (with lattice), the infill body and
the boundary body (final
geometry).

Figure 33

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 1. General overview

ICON COMMAND NAME DESCRIPTION

Generates a shell from implicit
solid body and infills it with
volume lattice. Inputs are the
SHELL AND VOLUME
solid body, lattice shape (from
LATTICE
the library), cell size and
rotation, lattice struts thickness,
shell thickness and blend radius.

Figure 34

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ICON COMMAND NAME DESCRIPTION

Generates a shell from implicit
body and infills it with gyroid
structure. Inputs are the solid
SHELL AND GYROID
body, cell size, lattice structure
thickness, shell thickness and
blend radius.

Figure 35

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 1. General overview

ICON COMMAND NAME DESCRIPTION

Generates a shell from implicit
solid body and infills it with
SHELL AND Voronoi lattice. Inputs are the
VORONOI LATTICE solid body, point spacing,
number of seed, struts thickness,
shell thickness and blend radius.

Figure 36

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The last section group is “Utilities”, which contains the blocks to modify and
correct lattice, mesh, etc.

ICON COMMAND NAME DESCRIPTION

Removes lattice struts (beams)
REMOVE ANY
which are inside a defined solid
BEAMS
body (input).

Figure 37

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 1. General overview

Figure 38

Figure 39

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ICON COMMAND NAME DESCRIPTION

REMOVE FLOATING Removes floating beams from a
BEAMS lattice structure (input).

REMOVE OPEN Removes open beams from a

BEAMS lattice structure (input).
Generates a mesh of an implicit
SIMPLE REMESH body by defining body feature
BODY size and mesh type (triangle,
quad or quad-dominated).
Generates a mesh of a CAD face
by defining target edge length,
REMESH CAD FACE
type of mesh (triangle, quad or
quad-dominated) and tolerance.
Compares the weight of original
WEIGHT SAVINGS
and lightweighted bodies.

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 1. General overview

ICON COMMAND NAME DESCRIPTION

Creates rib along a defined
EXTRUDE LATTICE
direction in a lattice body.

Figure 40

Figure 41

ICON COMMAND NAME DESCRIPTION

MIX Mixes scalar values.

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 7. Case study

187
Giorgio De Pasquale is a professor of machine design and building at the Politecnico
di Torino. As the head of the "Smart Structures and Systems" Lab, he leads
groundbreaking research in multifunctional structures, lightweight design, and
innovative processes and materials. Throughout his career, he has experienced
methods and models for multi-physics modeling, integrating experimental
mechanics and prototyping techniques. His contributions underscore his
unwavering commitment to advancing the frontiers of engineering, making him a
recognized figure in the field of mechanical and aerospace engineering.

Daniela Barra is a distinguished biomedical engineer, holding a degree from

Politecnico di Torino. Her academic prowess is evident through her master's thesis,
focusing on the innovative design and development of orthopedic insoles utilizing
lattice structures and 3D printing technology. With a commitment to pushing
boundaries, Daniela has contributed significantly to the realm of 3D printing, having
served as a project specialist in a leading company specializing in automotive,
aerospace, and arts applications. Presently, her expertise is dedicated to advancing
medical device production, showcasing her unwavering commitment to cutting-
edge technology and innovation.