biostudies-literatureBoddeti NDOD | Air Force Office of Scientific Research (AF Office of Scientific Research)DOD | Defense Advanced Research Projects Agency (DARPA)15560https://www.ebi.ac.uk/biostudies/studies/S-EPMC6197205biostudies-literatureUnknown8(1)The integration of emerging technologies into a complete digital thread promises to disrupt design and manufacturing workflows throughout the value chain to enable efficiency and productivity transformation, while unlocking completely new design freedom. A particularly appealing aspect involves the simultaneous design and manufacture of the macroscale structural topology and material microstructure of a product. Here we demonstrate such a workflow that digitally integrates: design automation - conception and automation of a design problem based on multiscale topology optimization; material compilation - computational geometry algorithms that create spatially-variable, physically-realizable multimaterial microstructures; and digital fabrication - fabrication of multiscale optimized components via voxel-based additive manufacturing with material jetting of multiple photo-curable polymers. We validate the digital design and manufacturing workflow by designing, fabricating, and testing a series of structures that illustrate capabilities, show how it empowers the exploitation of new design freedom, and even challenges traditional design principles relating form, structure, and function.Scientific reportsSimultaneous Digital Design and Additive Manufacture of Structures and Materials.PMC6197205HR0011-17-2-0022FA9550-1084 16-1-0169Kaijima SMaute KDunn MLBoddeti NDing ZfalseSimultaneous Digital Design and Additive Manufacture of Structures and Materials.The integration of emerging technologies into a complete digital thread promises to disrupt design and manufacturing workflows throughout the value chain to enable efficiency and productivity transformation, while unlocking completely new design freedom. A particularly appealing aspect involves the simultaneous design and manufacture of the macroscale structural topology and material microstructure of a product. Here we demonstrate such a workflow that digitally integrates: design automation - conception and automation of a design problem based on multiscale topology optimization; material compilation - computational geometry algorithms that create spatially-variable, physically-realizable multimaterial microstructures; and digital fabrication - fabrication of multiscale optimized components via voxel-based additive manufacturing with material jetting of multiple photo-curable polymers. We validate the digital design and manufacturing workflow by designing, fabricating, and testing a series of structures that illustrate capabilities, show how it empowers the exploitation of new design freedom, and even challenges traditional design principles relating form, structure, and function.2018-01-01T00:00:00Z2018 Oct2021-02-20T19:30:46Z2019-03-27T00:04:11ZS-EPMC61972053034894310.1038/s41598-018-33454-3