Although additive manufacturing (AM) has big potentials to print quite complex structures, the design and printing preparation is still quite chanllenge, especilly for complex fine porous structures. To avoid the accuracy loss along the AM processing chain, this research proposes to develop a new generative design for AM method, toolpath-based layer construction method. This method will use the physical deposition profile to define cellular layer patterns, and then apply knowledge based method with evolutionary algorithms to construct toolpath layers but not 2D contours slices to directly build a full processing model for printing. Advanced numerical simulation methods and printing quality evaluation and control methods will be developed to suport the decision making on design and processing compensation to ensure that the generated and identified optimal design solution is qualified. Industrial case studies will be conducted to demonstrate and promote the application. In the end, a design and printing preparation tool prototype will be developed on Rhino Grasshopper platform as an open source software tool to attract more public contributors to further develop and promote the new layer construction design method in AM.

Unlike for new on-road light-duty vehicles, for which mandatory carbon dioxide (CO2) emissions standards have been in place in the European Union (EU) for a decade, the CO2 emissions standards for new on-road Heavy-Duty Vehicles (HDV) were only adopted in 2019. This delay is particularly due to more stringent requirements, to substitute the diesel engine-based HDV, in terms of lifetime, driving range or refueling time. Today, a fast deployment of new types of on-road HDV to reduce the ecological footprint of transportation is then required. To tackle this, the EU aims to deploy zero-emission vehicles using battery or hydrogen fuel cell. In order to expect a rapid growth of these vehicles the trend is to develop scalable and modular platforms. Applied to the power supplies, the modular and scalable platforms result to use multi-module batteries and multi-stack fuel cells. For this purpose, MARSHALL (ModulAR and Scalable battery and fuel cell systems for on-road HeAvy-duty eLectrified vehicLes) is a new project, within the framework of the French national network MEGEVH on the electrified vehicles, between three labs; Ampère, FEMTO-ST and L2EP; to develop a generic methodology for the design of multi-module batteries and multi-stack fuel cells applied to on-road HDV. The ambition of the project is to accelerate the system architecture design process of the battery and fuel cell systems by at least 20%, thereby reducing the time-to-market of battery and fuel cell HDV. This will be done by using Energetic Macroscopic Representation (EMR) formalism to develop innovative scaling and modularizing laws that allow to up- or down-size reference components, making it needless to redo time consuming design steps. Also, the applicability of the method will be assessed for eco-design of multi-module batteries and multi-stack fuel cells. Dedicated setups will be used to prove the effectiveness of the methodology.