Metal AM parts take two awards in purmundus challenge

November 19, 2021

The Toucan Beak (left) won the Simulation Driven Design Award. A Newcomer Prize was awarded for the development of an additively manufactured brake caliper (right) (Copyright Metal AM)

Winners of the purmundus challenge were announced at Formnext 2021, with metal additively manufactured parts taking the Simulation Driven Design Award and Newcomer Prize. The first, second and third prizes of the challenge were awarded to polymer AM components, including (first) New Pointe Shoe Sole from Sophia Lindner, act’ble GmbH; (second) Travel Sax from Ramon Mañas, Odisei Music SL; and (third) HEXR, The World’s First Custom Fit Bicycle Helmet from Jamie Cook, Henry Neilson, Theo Clarkes, Mark Brown, Jess Lewis and George Jary, HEXR.

The 2021 Altair Simulation Driven Design Award went to Tommaso Tirelli of Aidro (a Desktop Metal company), Taino, Italy, for the Toucan Beak, an efficient, low-weight, low-carbon-footprint heat exchanger. The microchannel structures were designed through topological optimisation and machine learning simulation (AI) and enabled by high-performance computers before being produced using Laser Beam Powder Bed Fusion (PBF-LB).

The Newcomer Prize was awarded to Aschraf Danun, Michael Wehrli, Remo Elmiger, Ole Müller, Tiago Ogris, Tom Felder and Prof. Mirko Meboldt from ETH Zurich – Product Development Group Zurich, Switzerland, for the development of an additively manufactured brake caliper with greater design freedom for internal channels, functional integration of a monolithic compliant membrane and topology optimised lightweight design.

Further detail on the metal AM finalists is available in our previous coverage.

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As well as an extensive AM industry news section, this 226-page issue includes articles and reports on:

  • Metal AM in hydraulics: Aidro’s Valeria Tirelli on opportunities, applications, and joining Desktop Metal
  • I want to break free: The journey towards reducing or eliminating support structures
  • Simufact Additive: Accelerating the Metal Binder Jetting workflow with sintering simulation
  • Metal powder characterisation for Additive Manufacturing: Beyond state-of-the-art standards
  • A look at the future: What does the next decade hold for metal Additive Manufacturing?
  • Reducing residual stress with 500°C build chamber preheating for ‘first time right’ PBF-LB
  • Separating metal AM parts from the build plate – an underestimated challenge
  • How X-ray Computed Tomography is helping an AM service bureau to improve predictive-model based qualification
  • > More information

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