Altair > Case Studies > Optimising 3D Printed Stool Design with solidThinking Inspire: A Case Study on Assa Ashuach Studio

Optimising 3D Printed Stool Design with solidThinking Inspire: A Case Study on Assa Ashuach Studio

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Technology Category
  • Functional Applications - Manufacturing Execution Systems (MES)
  • Sensors - Lidar & Lazer Scanners
Applicable Industries
  • Electronics
  • Life Sciences
Applicable Functions
  • Product Research & Development
Use Cases
  • Additive Manufacturing
  • Time Sensitive Networking
About The Customer
Assa Ashuach Studio is a London-based industrial research and product design consultancy that designs and manufactures lifestyle products and limited edition studio pieces. The studio employs a network of highly skilled specialists from the design, science, and manufacturing sectors, using dedicated 3D software development, electronics, and engineering as an integrated part of its design methodologies and philosophy. The studio is led by Director Assa Ashuach, who is always looking for innovative ways to design and manufacture products that are unique in form and aesthetic quality.
The Challenge
Assa Ashuach Studio, a London-based industrial research and product design consultancy, was faced with the challenge of designing a stool that was both light and economical. The stool needed to be customised to support a weight of 120 kg. The challenge was to determine how much material could be removed from the design space while still supporting this weight and achieving a unique design. The design and manufacturing process had to be efficient, reducing material waste and cost, without compromising on the quality of the product. The studio was also interested in exploring new design and production methods to achieve unique forms and aesthetic qualities.
The Solution
The solution came in the form of Altair's solidThinking Inspire, a software that uses industry-leading OptiStruct technology to enable product designers to generate and investigate structurally efficient concepts quickly and easily. The software allows designers to import their design, create the design space, and then define materials and loading conditions. From this point, the ideal material layout is generated which can then be controlled to achieve the desired result of the final design. In this project, Inspire removed any redundant material according to stress zones on the object surface. An optimisation of the exterior and material use was made to achieve a light and economical form. The stool was produced by laser sintering, which allowed for a faster production time and energy savings by reducing the laser millage and distance to the final object layer.
Operational Impact
  • The use of solidThinking Inspire in the design process of the stool resulted in a product where aesthetics met performance. The final concept of the stool was reanalysed using OptiStruct, simulating a 120 kg distributed load on the seating area. The analysis results confirmed the structural integrity of the stool. The stool was made of Nylon 12, a material commonly used for plastic additive layer manufacturing. The Femur Stool was showcased as part of 'The Future is Here' exhibition at London Design Museum and also at 'The Language of Process' exhibition in the Manchester Metropolitan University Special Collections Gallery. It is also on display at London Science Museum for the duration of 2014.
Quantitative Benefit
  • Faster production time due to the use of laser sintering
  • Energy savings achieved by reducing the laser millage and distance to the final object layer
  • Material savings due to the removal of redundant material according to stress zones on the object surface

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