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Redefining Design for Remanufacturing: A Practical Methodology for Prioritizing Remanufacturing Design Rules
Products are often discarded when they fail or no longer meet user needs. These outcomes are frequently shaped by early design decisions. While remanufacturing offers a sustainable alternative by restoring products to like‐new condition, its potential is often limited by designs that do not consider remanufacturing from the outset. This research addresses that challenge by introducing a structured Design for Remanufacturing (DfRem) methodology and a CAD‐integrated tool to support real‐time design decisions. The DfRem framework introduces a new primary design function focused on preserving product functionality across its life cycle. It is supported by a fault tree that identifies failure modes that limit remanufacturing potential and a hierarchy of design principles including Prevent, Minimize, Relocate, Restore, and others. Each principle is linked to actionable design rules that help engineers reduce the need for remanufacturing or improve its efficiency when necessary. To operationalize this framework, we developed CAD plugins for Autodesk Inventor and PTC Creo. These tools use a state machine model to present prioritized design rules based on selected failure modes and user input. By embedding DfRem logic directly into widely used CAD environments, the tool enables engineers to make sustainability‐informed decisions without disrupting existing workflows. Furthermore, this approach highlights the critical role of design in enabling circular and resource‐efficient product development, making remanufacturing a more practical and accessible strategy during the early stages of product design.
Optimization of the Second Target Station cold source moderators using an automated workflow
The Second Target Station (STS) at the US Department of Energy’s Oak Ridge National Laboratory is designed to become the world’s highest peak-brightness spallation source of cold neutrons. Successful completion of the STS, which is currently in the preliminary design phase, will provide transformative new capabilities to examine novel materials for future technologies. At STS, neutrons will be generated by spallation reactions in a solid tungsten target. They will be moderated and thermalized in two cold (20 K) para-hydrogen moderators. Careful optimization of these moderators is essential to the project’s success. To find optimal moderator designs, an advanced optimization workflow integrates high-fidelity neutronics calculations using the Monte Carlo N-Particle (MCNP) transport code MCNP6.2 with state-of-the-art optimization algorithms in the Dakota optimization toolkit. For each design iteration, a parametrized solid CAD geometry is generated in Creo and automatically converted into an unstructured mesh geometry by Attila 4MC for the neutronics calculation with MCNP. Iterations repeat until optimal designs are found. Herein this paper presents the results of a sensitivity and optimization study for the cylindrical and tube moderators. Both moderators can be optimized for maximum peak brightness, maximum time-integrated brightness, or any combination between these extremes. Maximum peak brightness is achieved by using smaller optimal dimensions of the moderators, whereas maximum time-integrated brightness is achieved by using larger dimensions. A Pareto front details the designs that optimally balance both brightness metrics. The Pareto front can be found in only 40–110 iterations with 4–5 design parameters when using the efficient global and Pareto-set optimization algorithms in Dakota. Additionally, important engineering constraints can be taken into account, such as the coupling between the cylindrical moderator radius and aluminum vessel wall thicknesses required to ensure structural integrity of the vessels. This interaction has a significant impact on the resulting optimal designs. Our new, highly efficient, fully automated optimization workflow will be used to optimize additional STS components in the future and can be adopted for design and optimization studies at other experimental neutron and accelerator facilities.
Advancing the STS Neutron Moderator Design with an Automated Optimization Workflow and Unstructured Mesh Modeling
With the Second Target Station approaching its final design phase, a detailed neutronics evaluation of its critical components is necessary. Optimizing the dimensions of the two cold-source moderators that are at the heart of this facility presents a multi-objective optimization problem for which an accurate geometric description is crucial. We have applied a fully automated optimization workflow in which a detailed unstructured mesh geometry is automatically generated with Attila4MC, starting from a parametrized CREO geometry followed by preprocessing with SpaceClaim. With this geometry, a MCNP run is performed to calculate the brightness metrics, which are subsequently provided to the optimization algorithm in DAKOTA that provides new parameters and drives the optimization loop until convergence. In this paper, we show the results of the analysis that are used for the final design of the cylindrical and tube moderator. The optimization simulations provide a refinement to and confirmation of the conclusions of the previous design iteration. Additional to the optimization, a sensitivity study is performed to study the effect of minor geometry changes, which is important for the final engineering design. In conclusion, with these studies, we demonstrate that the automated workflow and high-fidelity unstructured mesh modeling are efficient tools for a thorough design evaluation.
Mass Property Calculator
A mass property calculator has been developed to compute the moment of inertia properties of an assemblage of parts that make up a system. The calculator can take input from spreadsheets or Creo mass property files or it can be interfaced with Phoenix Integration Model Center. The input must include the centroidal moments of inertia of each part with respect to its local coordinates, the location of the centroid of each part in the system coordinates and the Euler angles needed to rotate from the part coordinates to the system coordinates. The output includes the system total mass, centroid and mass moment of inertia properties. The input/output capabilities allow the calculator to interface with external optimizers. In addition to describing the calculator, this document serves as its user's manual. The up-to-date version of the calculator can be found in the Git repository https://cee-gitlab.sandia.gov/cj?ete/mass-properties-calculator.
CrossLink: Geometry API [Slides]
The mesh generation process is very challenging and time consuming when working with complex CAD models. The process of creating and sorting geometric entities into groups appropriate for meshing is labor intensive and prone to error. In addition, the common data exchange formats such as STEP and IGES do not propagate information such as entity names that may be defined in the original model. Finally, entity counts change frequently with parameter variation as a result of tolerance-based geometry operations. Thus, sorting by index does not provide a robust and repeatable means for grouping. xGeom is a geometry library that enables the creation of NURBS curves and surfaces via a python scripting interface. xGeom is ideal for studying relatively simple models and is fully integrated with CrossLink’s mesh generation capabilities. For more complex models, xCAD is a python-based Creo Parametric CAD model driver that enables the model to be generated, queried, parametrically modified, regenerated, and exported without data loss and in a fully repeatable manner.
Resumen del Informe de Progreso del PR100: Resultados Preliminares del Modelo y Conjuntos de Datos Solares y Eólica de Alta Resolución
El estudio de Resiliencia y Transiciones a 100% Energia Renovable de Puerto Rico (PR100) es un estudio de 2 anos de la Oficina de Movilizacion de la Red del Departamento de Energia y seis laboratorios nacionales para analizar exhaustivamente las rutas dirigidas por las personas interesadas hacia un futuro de energia limpia en Puerto Rico. En el Ano 1 del estudio, el equipo PR100, creo y analizo los modelos que alcanzan las metas de energia renovable para Puerto Rico y los objetivos de resiliencia energetica a corto y largo plazo. Este informe, que resume el progreso en el Ano 1, proporciona las consideraciones que pueden informar posibles decisiones de fondos e implementacion potenciales por parte de las agencias federales y locales clave y partes interesadas. El resumen de este informe sigue a la publicacion en julio 2022 de un Informe de Seis Meses de Progreso de PR100. (en ingles y espanol), asi como webinarios publicos en febrero 2022 para lanzar el estudio y julio 2022 para presentar la actualizacion a 6 meses. Un informe final por escrito y visuales por la web seran publicados a finales del 2023. Todas las publicaciones y eventos publicos asociados con el estudio estaran disponibles en ingles y espanol. This report is also available in English https://www.nrel.gov/docs/fy23osti/85018.pdf.
CrossLink: Meshing a 3D part from a STEP file [Slides]
This example shows how to use CrossLink to create a mesh for a 3D geometry part read in from a STEP file. A STEP file (Standard for the Exchange of Product data) is a common file format used for 3D modelling that can be written out from a CAD program (e.g., Creo Parametric). Being able to read and mesh STEP file geometries is essential for meshing parts from engineering models. Creating the mesh typically involves: (1) Importing the geometry; (2) Creating geometry groups; (3) Assigning curves and surfaces to the geometry groups; (4) Building a topology; (5) Applying geometric and mesh constraints; and (6) Generating the final mesh. Current issues with this process in CrossLink include: (1) The GUI does not display trimmed surfaces; (2) The user must manually create and assign geometry groups; and (3) The user must be aware of duplicate curves and surfaces from the CAD model.
Augmenting the Structural Dynamics Workflow to Reduce Development Times [Slides]
The structural dynamics workflow at LANL stands to be improved by implementing methods and techniques related to reduced-order finite-element modeling (FEM), pretest predictions, and FEM-test correlation and updating. The benefits of these industry-standard practices are demonstrated in this work. Software used for this project included Ansys 2023 R2 (Mechanical and Spaceclaim), Creo Parametric 8.0, MathCAD Prime 8.0, Matlab R2023b.
Optimization of the moderators in the STS preliminary design
This report details the results for an optimization of the dimensions of the moderators in the preliminary design of the Spallation Neutron Source Second Target Station (STS). This study uses the optimization algorithms of Dakota and an unstructured mesh model for the moderators in MCNP. More details on the unstructured mesh model and the automated mesh generation can be found in [3]. Parallel to this effort, the same moderator geometries have been optimized using a constructive solid geometry (CSG) MCNP model. More details on this model and its results can be found in [4]. Three optimal designs are selected for each moderator: one that is optimized for maximum peak brightness, one for maximum time-integrated brightness, and one for a combination of peak and time-integrated brightness. The backbone of the optimization work flow is provided by Dakota. For each set of design parameters requested by Dakota, a new solid geometry is automatically built in Creo and SpaceClaim, and subsequently exported to Attila4MC to generate an unstructured mesh geometry for MCNP. After the MCNP calculation is finished, the objective function (e.g., brightness metric) is returned to Dakota. After the new design has been evaluated, a result-file is written, and Dakota proposes the next set of design parameters to be evaluated. The loop continues until a specified convergence criterion has been met. The design parameters of the cylindrical (upper) moderator include the hydrogen radius, the premoderator thickness (top, bottom, radial), the beryllium radius and the horizontal position of the moderator. The crucial design choice is the hydrogen radius. A radius of 62 mm is shown to provide the maximum time-integrated brightness. The maximum peak brightness occurs with a radius of 40 mm. A combined (middle) design, which balances peak and time-integrated brightnesses, is obtained with a hydrogen radius of 50 mm. The premoderator thicknesses and the beryllium radius are slightly larger in the design optimized for time-integrated brightness than in the design optimized for peak brightness. The sensitivity to these two parameters is relatively small close to the optimal configurations. The hydrogen vessel and vacuum vessel wall thicknesses are dependent on the radius of the liquid hydrogen due to structural integrity requirements. The increased wall thicknesses for larger vessels significantly penalize the time-integrated brightness, with the maximum obtainable value reduced by more than 10% relative to earlier studies which used fixed vessel wall thicknesses. The impact of the variable wall thicknesses is much less for the peak brightness and combined brightness designs. The design parameters of the tube (lower) moderator selected for the optimization are the tube length, the annular premoderator thickness, the beryllium radius and the horizontal position of the moderator. The tube length is the crucial parameter and is chosen large (210 mm) and small (125 mm) in the designs optimized for time-integrated and peak brightness respectively. A combined optimal design has a tube length of 170 mm. The premoderator thickness and the beryllium radius are chosen larger in the design optimized for time-integrated brightness.
Coupled Target-Beam-Moderator Optimization for the Second Target Station
This report describes the results for a coupled target-beam-moderator optimization analysis for the Second Target Station (STS) at ORNL's Spallation Neutron Source. This study is a continuation of the optimization analysis for the moderators in the preliminary design of STS performed in 2022. In the 2022 analysis the dimensions of the moderators are parameterized, while the target and the proton beam profile are kept constant. In this analysis the target height and the proton beam profile are added as parameters. This allows to study the coupled effects of changing target, moderator and beam dimensions. Similar to the 2022 analysis, this work is performed with an automated optimization workflow that uses the optimization toolbox DAKOTA, parameterized geometries in CREO and SpaceClaim, the unstructured mesh generation in Attila4MC, and the particle transport code MCNP6.2©. This workflow enables an efficient optimization using high-fidelity geometries. The main conclusions of this analysis are the following: • Coupled beam-target-moderator optimization provides a few additional percent performance gain over stand-alone moderator optimization. • The moderator performance is not very sensitive to the target height (between ≈60 and ≈80 mm) as long as the beam profile is chosen adequately. • The moderator performance is sensitive to the choice of beam spatial standard deviations, even when the footprint is kept constant. • The optimal moderator radius is the same for a beam footprint of 30 cm 2 , 62.5 cm 2 , and 90 cm 2 . Also the slope of the super-gaussian beam profile does not significantly impact the optimal moderator radius. • The optimal parameters and sensitivities are very similar to the 2022 optimization analysis. These results only indicate a a difference in the optimal radius of the cylindrical moderator, however, this has been corrected in the final design moderator optimization. The main purpose of this report is to document the simulations, results and lessons learned. The most impactful results are summarized in. We also note that the target geometry used in this work is not the final design.
Avances a un ano del PR100: Resultados Preliminares del Modelzacion y Conjuntos de Datos Solares y Eolicos de Alta Resolucion
El estudio de Resiliencia y Transiciones a 100% Energia Renovable de Puerto Rico (PR100) es un estudio de 2 ano de la Oficina de Movilizacion de la Red del Departamento de Energia y seis laboratorios nacionales para analizar exhaustivamente las rutas dirigidas por las personas interesadas hacia un futuro de energia limpia en Puerto Rico. En el Ano 1 del estudio, el equipo PR100, creo y analizo los modelos que alcanzan las metas de energia renovable para Puerto Rico y los objetivos de resiliencia energetica a corto y largo plazo. Esta presentacion, que resume el progreso en el Ano 1, proporciona las consideraciones que pueden informar posibles decisiones de fondos e implementacion potenciales por parte de las agencias federales y locales clave y partes interesadas. Esta presentacion sigue a la publicacion en julio 2022 de un Informe de Seis Meses de Progreso de PR100 (en ingles y espanol), asi como webinarios publicos en febrero 2022 para lanzar el estudio y julio 2022 para presentar la actualizacion a 6 meses. Un informe final por escrito y visuales por la web seran publicados a finales del 2023. Todas las publicaciones y eventos publicos asociados con el estudio estaran disponibles en ingles y espanol. This report is also available in English https://www.nrel.gov/docs/fy23osti/85126.pdf.