Controlling local overheating in topology optimization for additive manufacturing

A novel constraint to prevent local overheating is presented for use in topology optimization (TO). The very basis for the constraint is the Additive Manufacturing (AM) process physics. AM enables fabrication of highly complex topologically optimized designs. However, local overheating is a major concern especially in metal AM processes...

Simultaneous topology and deposition direction optimization for Wire and Arc Additive Manufacturing

A remarkable elastic anisotropy in plates of austenitic stainless steel produced by the Wire and Arc Additive Manufacturing process is recently reported. The Young's modulus depends on the angle of orientation with respect to the material deposition direction. Here, for the first time, this anisotropy is exploited to maximize structural...

Overhang control in topology optimization: a comparison of continuous front propagation-based and discrete layer-by-layer overhang control

Although additive manufacturing (AM) allows for a large design freedom, there are some manufacturing limitations that have to be taken into consideration. One of the most restricting design rules is the minimum allowable overhang angle. To make topology optimization suitable for AM, several algorithms have been published to enforce a minimum...

Overhang control based on front propagation in 3D topology optimization for additive manufacturing

It is attractive to combine topology optimization (TO) with additive manufacturing (AM), due to the design freedom provided by AM, and the increased performance that can be achieved with TO. One important aspect is to include the design rules associated with the process restrictions of AM to prevent the requirement of relatively large support...

High-precision motion system design by topology optimization considering additive manufacturing

In the design process of high-precision motion stages, the dynamic behavior is of paramount importance. Manual design of such a stage is a time-consuming process, involving many iterations between engineers responsible for mechanics, dynamics and control. By using topology optimization in combination with additive manufacturing, post...

Space-time topology optimization for additive manufacturing: Concurrent optimization of structural layout and fabrication sequence

The design of optimal structures and the planning of (additive manufacturing) fabrication sequences have been considered typically as two separate tasks that are performed consecutively. In the light of recent advances in robot-assisted (wire-arc) additive manufacturing which enable addition of material along curved surfaces, we present a...

Continuous front propagation-based overhang control for topology optimization with additive manufacturing

Additive manufacturing enables the nearly uncompromised production of optimized topologies. However, due to the overhang limitation, some designs require a large number of supporting structures to enable manufacturing. Because these supports are costly to build and difficult to remove, it is desirable to find alternative designs that do not...

Computational time issues of AM process simulations with a view to large-scale topology optimization

Overhang free topology optimization applied to flow optimization

A semi-analytical thermal model of selective laser melting process

A computationally efficient process modelling approach for selective laser melting