A two-stage structural optimisation and thermal discretisation of non-convective structured insulators: applications in granular-solid structures by additive manufacturing technology

A systematic design procedure for characterising the strength and insulation requirements of a modular unit structure from additive manufacturing has been presented. The proposed 'two-stage' method consists of structural optimisation and thermal 'discretisation', through use of the Metamorphic Development (MD) and Discretisation by Partitioning Method (DbPM), respectively. A structural layout optimisation method of a consolidated granular-solid structure for strength requirements is demonstrated. The reliability of the layout optimized design solution tested using experiments and finite element analysis (PEA) are reproduced with reasonable accuracy. Layout optimisation yielded 40% savings in build material, whilst satisfying the targeted deflection. [Continues.]