In the realm of marine engineering, a groundbreaking study led by Margarida Mata from the Department of Metallurgical and Materials Engineering at the Faculty of Engineering, University of Porto, is set to revolutionize the design and manufacturing of hydrofoil components for unmanned boats. The research, which has been published in ‘Academia Materials Science’ (translated to English is ‘Academic Materials Science’), focuses on leveraging advanced design techniques and additive manufacturing to enhance the performance and efficiency of hydrofoil wings.
Hydrofoils, known for their ability to generate lift forces that elevate boats above water, are crucial for increasing speed and reducing drag. Mata and her team have developed a mechanism using Fusion 360 to adjust the angle of attack of these hydrofoil wings, a critical feature for optimizing performance under varying conditions. The real innovation, however, lies in the application of topology optimization (TO) and generative design techniques to reduce the weight of these components without compromising their structural integrity.
The study utilized nTop and Eiger software to optimize the hydrofoil components for additive manufacturing (AM), with a particular focus on weight reduction. Material extrusion, a form of AM, was chosen as the preferred technology. The researchers adapted the workflow within nTop for two materials: Onyx and carbon fiber-reinforced Onyx. “Generative design techniques, including field-driven design, lattice structures, and topology optimization, played a pivotal role in achieving our goals,” Mata explained. “Variable-thickness shells proved to be an efficient approach for reducing mass while preserving mechanical integrity.”
The results were impressive. Topology optimization of the lever component resulted in a significant reduction in mass, highlighting the potential of these advanced design techniques in creating lighter, more efficient hydrofoil components. This breakthrough could have profound implications for the energy sector, particularly in reducing the operational costs and environmental impact of marine vessels.
The implications of this research extend beyond unmanned boats. The use of topology optimization and additive manufacturing could pave the way for more efficient and sustainable marine technologies. As Mata noted, “The integration of these advanced design techniques with additive manufacturing opens up new possibilities for creating lightweight, high-performance components that can be applied across various industries.”
The study, published in ‘Academia Materials Science’, underscores the transformative potential of combining advanced design software with additive manufacturing technologies. As the marine industry continues to evolve, innovations like these will be crucial in driving forward the development of more efficient and sustainable marine vessels. The research by Margarida Mata and her team at the University of Porto is a testament to the power of interdisciplinary collaboration and cutting-edge technology in pushing the boundaries of what is possible in marine engineering.