Extensions of Topology Optimization for Additive Manufacturing

This research proposes topology optimization methods that allow additive manufacturing-related considerations to be integrated in the designs. The objective of this research is to establish a connection between topology optimization and additive manufacturing, with a specific focus on enhancing the manufacturability of designs derived from topology optimization. Our aim is to illustrate that by incorporating real-world additive manufacturing process conditions into the optimization problem, topology optimization can produce improved designs with better performance.

We want to demonstrate that topology optimization can be a design tool for additive manufacturing. This research, brings benefit to both fields. In the aspect of topology optimization: Topology optimized designs are made more meaningful and “AM-friendly”, for they represent the true optimal geometry or mechanical performance of the fabricated part, after effects of AM process characteristics and limitations are considered in the optimization, for example, inaccessibility of support structure at enclosed voids, and the need for support structure at overhanging geometry. This shows that topology optimization can generate better designs in the design for additive manufacturing (DfAM) process. In the aspect of AM: The improved manufacturability of topology optimized designs eases transition from optimal design to final part fabrication. Application of AM in printing critical components is made more reliable, as mechanical properties of the as-printed part are more accurately estimated during TopOpt using realistic material properties. This research can be applied to fields in which it is beneficial to use DfAM for making reliable products at lower costs, such as in the aerospace and automotive fields.