Generative shell design for simulations

1. A computer-implemented method for generating models, comprising:

generatively creating, until convergence is reached via a generative design process within a generative design software application, a generative shelled base, wherein the generative shelled base comprises a hollow computer-aided design (CAD) three-dimensional (3D) design;

creating, from the generative shelled base, a shell CAD geometry and a shell mesh model;

creating, from the shell CAD geometry, a support structure mid-surface shell of an internal support structure for the generative shelled base;

combining the support structure mid-surface shell with the shell mesh model into a generative mid-surface mesh;

providing the generative-mid-surface mesh to a computer-aided engineering (CAE) crash simulation application for validation of the generative mid-surface mesh;

combining the generative shelled base with the shell CAD geometry into a generative shelled solid; and

providing the generative shelled solid to an additive build simulation application; and

wherein the shell CAD geometry is used to create both the generative mid-surface mesh that is used by CAE crash simulation application, and the generative shelled solid that is used by the additive build simulation application.

2. The computer-implemented method of claim 1 , wherein the creating the generative shelled base comprises:

creating a generative design for a solid CAD design, wherein the creating the generative design comprises creating obstacles and applying boundary conditions with constraints;

generating one or more outcomes based on the generative design, wherein the one or more outcomes:

comprise a historical recipe for creating the generative design; and

are based on stress forces that are applied to the generative design;

analyzing the one or more outcomes and the generative design, wherein the analyzing comprises adding a t-spline to the historical recipe;

calculating a safety factor for the generative design based on the historical recipe; and

iterating the creating the generative design by adjusting the safety factor until an optimized generative shelled base is acquired.

3. The computer-implemented method of claim 2 , wherein the creating the generative shelled base is performed by a solver that generates a t-spline of the generative shelled base in a uniform thickness.

4. The computer-implemented method of claim 1 , wherein the internal support structure does not trap powder and is shaped to provide inertia against bending.

5. The computer-implemented method of claim 1 , wherein the shell CAD geometry is created by:

creating, from the generative shelled base, a t-spline body, wherein the creating the t-spline solid body comprises:

acquiring an outer t-spline face from the generative shelled base; and

offsetting the outer t-spline face by a defined thickness to create an inner surface resulting in the t-spline solid body.

6. The computer-implemented method of claim 1 , wherein the creating the shell mesh model comprises:

creating, from the generative shelled base, a t-spline mid-surface shell, wherein the creating of the t-spline mid-surface shell comprises:

acquiring an outer t-spline face from the generative shelled base; and

offsetting the outer t-spline face by a defined thickness to create an inner surface resulting in the t-spline mid-surface shell.

7. The computer-implemented method of claim 1 , wherein the combining the support structure mid-surface shell with the shell mesh model comprises a Boolean operation.

8. The computer-implemented method of claim 1 , wherein the combining the generated shelled base with the shell CAD geometry comprises a Boolean operation.

9. The computer-implemented method of claim 1 , wherein the combining the support structure mid-surface shell with the shell mesh model further comprises:

intersecting an internal support structure, of the generative shelled base, with a face of the shell mesh model; and

deleting a portion of the internal support structure that extends beyond the face.

10. A computer-implemented system for generating models, comprising:

(a) a computer having a memory;

(b) a processor executing on the computer;

(c) the memory storing a set of instructions, wherein the set of instructions, when executed by the processor cause the processor to perform operations comprising:

(i) generatively creating, until convergence is reached, a generative shelled base, wherein the generative shelled base comprises a hollow computer-aided design (CAD) three-dimensional (3D) design;

(ii) creating, from the generative shelled base, a shell CAD geometry and a shell mesh model;

(vii) creating, from the shell CAD geometry, a support structure mid-surface shell of an internal support structure for the generate shelled base;

(viii) combining the support structure mid-surface shell with the shell mesh model into a generative mid-surface mesh, and providing the generative-mid-surface mesh to a computer-aided engineering (CAE) crash simulation application for the validation of the generate mid-surface mesh; and

(ix) combining the generative shelled base with the shell CAD geometry into a generative shelled solid, and providing the generative shelled solid to an additive build simulation application; and

wherein the shell CAD geometry is used to create both the generative mid-surface mesh that is used by CAE crash simulation application, and the generative shelled solid that is used by the additive build simulation application.

11. The computer-implemented system of claim 10 , wherein the creating the generative shelled base comprises:

creating a generative design for a solid CAD design, wherein the creating the generative design comprises creating obstacles and applying boundary conditions with constraints;

generating one or more outcomes based on the generative design, wherein the one or more outcomes:

comprise a historical recipe for creating the generative design; and

are based on stress forces that are applied to the generative design;

analyzing the one or more outcomes and the generative design, wherein the analyzing comprises adding a t-spline to the historical recipe;

calculating a safety factor for the generative design based on the historical recipe; and

iterating the creating the generative design by adjusting the safety factor until an optimized generative shelled base is acquired.

12. The computer-implemented system of claim 11 , wherein the creating the generative shelled base is performed by a solver that generates a t-spline of the generative shelled base in a uniform thickness.

13. The computer-implemented system of claim 10 , wherein the internal support structure comprises does not trap powder and is shaped to provide inertia against bending.

14. The computer-implemented system of claim 10 , wherein the shell CAD geometry is created by:

creating, from the generative shelled base, a t-spline body, wherein the creating the t-spline solid body comprises:

acquiring an outer t-spline face from the generative shelled base; and

offsetting the outer t-spline face by a defined thickness to create an inner surface resulting in the t-spline solid body.

15. The computer-implemented system of claim 10 , wherein the creating the shell mesh model comprises:

creating from the generative shelled base, a t-spline mid-surface shell, wherein the creating the t-spline mid-surface shell comprises:

acquiring an outer t-spline face from the generative shelled base; and

offsetting the outer t-spline face by a defined thickness to create an inner surface resulting in the t-spline mid-surface shell.

16. The computer-implemented system of claim 10 , wherein the combining the support structure mid-surface shell with the shell mesh model comprises a Boolean operation.

17. The computer-implemented system of claim 10 , wherein the combining the generated shelled base with the shell CAD geometry comprises a Boolean operation.

18. The computer-implemented system of claim 10 , wherein the combining the support structure mid-surface shell with the shell mesh model further comprises:

intersecting an internal support structure, of the generative shelled base, with a face of the shell mesh model; and

deleting a portion of the internal support structure that extends beyond the face.