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Holistic computational design within additive manufacturing through topology optimization combined with multiphysics multi-scale materials and process modelling

Bayat, Mohamad (author), Zinovieva, Olga (author), Ferrari, Federico (author), Ayas, C. (author), Langelaar, Matthijs (author), Spangenberg, Jon (author), Salajeghe, Roozbeh (author), Poulios, Konstantinos (author), Mohanty, Sankhya (author), Sigmund, Ole (author), Hattel, Jesper (author)

Additive manufacturing (AM) processes have proven to be a perfect match for topology optimization (TO), as they are able to realize sophisticated geometries in a unique layer-by-layer manner. From a manufacturing viewpoint, however, there is a significant likelihood of process-related defects within complex geometrical features designed by TO...

review 2023

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Prevention of enclosed voids in topology optimization using a cumulative sum flood fill algorithm

van der Zwet, J.M. (author), Delissen, A.A.T.M. (author), Langelaar, Matthijs (author)

Topology optimization has seen increased interest with the rise of additive manufacturing (AM) as a fabrication method, because of its ability to exploit the geometric complexity that AM offers. However, AM still imposes some geometric restrictions on the design, most notably on minimum feature size, overhang angles, and enclosed voids....

journal article 2023

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Controlling local overheating in topology optimization for additive manufacturing

Ranjan, R. (author), Ayas, C. (author), Langelaar, Matthijs (author), van Keulen, A. (author)

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...

journal article 2022

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

Mishra, V. (author), Ayas, C. (author), Langelaar, Matthijs (author), van Keulen, A. (author)

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...

journal article 2022

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Development of a Workflow for Designing Patient-Specific Mandibular Reconstruction Implants and Predicting their Performance through Experimentally Validated Finite Element Models

van Kootwijk, Arthur (author)

Restoration of the normal mandibular form and function is attempted with reconstructive surgery. The current standard procedure to restore continuity defects of the mandible involves free tissue transfer with an autologous bone flap. Even though the success rates are high, several critical drawbacks have been associated with this procedure,...

master thesis 2021

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Topology optimization of multi-scale structures: a review

Wu, J. (author), Sigmund, Ole (author), Groen, Jeroen P. (author)

Multi-scale structures, as found in nature (e.g., bone and bamboo), hold the promise of achieving superior performance while being intrinsically lightweight, robust, and multi-functional. Recent years have seen a rapid development in topology optimization approaches for designing multi-scale structures, but the field actually dates back to...

review 2021

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

van de Ven, E.A. (author), Maas, Robert (author), Ayas, C. (author), Langelaar, Matthijs (author), van Keulen, A. (author)

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...

journal article 2021

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Topology Optimization for additive manufacturing with distortion constraints

Misiun, Grzegorz (author), van de Ven, E.A. (author), Langelaar, Matthijs (author), Geijselaers, Hubert (author), van Keulen, A. (author), van den Boogaard, Ton (author), Ayas, C. (author)

An important cause of failure in powder bed additive manufacturing is the distortion of the part due to thermal shrinkage during printing and the relaxation of residual stresses after its release from the base plate. In this paper, Additive Manufacturing simulations are coupled with Topology Optimization in order to generate designs that are...

journal article 2021

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

van de Ven, E.A. (author), Maas, Robert (author), Ayas, C. (author), Langelaar, Matthijs (author), van Keulen, A. (author)

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...

journal article 2020

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

Delissen, A.A.T.M. (author), Laro, Dick (author), Kleijnen, Harry (author), van Keulen, A. (author), Langelaar, Matthijs (author)

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...

conference paper 2020

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Integrated component-support topology optimization for additive manufacturing with post-machining

Langelaar, Matthijs (author)

Purpose: The purpose of this paper is to communicate a method to perform simultaneous topology optimization of component and support structures considering typical metal additive manufacturing (AM) restrictions and post-print machining requirements. Design/methodology/approach: An integrated topology optimization is proposed using two density...

journal article 2019

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

Wang, W. (author), Munro, D.P. (author), Wang, C.C. (author), van Keulen, A. (author), Wu, J. (author)

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...

journal article 2019

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Combined optimization of part topology, support structure layout and build orientation for additive manufacturing

Langelaar, Matthijs (author)

Additive manufacturing (AM) enables the fabrication of parts of unprecedented complexity. Dedicated topology optimization approaches, that account for specific AM restrictions, are instrumental in fully exploiting this capability. In popular powder-bed-based AM processes, the critical overhang angle of downward facing surfaces limits...

journal article 2018

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

van de Ven, E.A. (author), Maas, Robert (author), Ayas, C. (author), Langelaar, Matthijs (author), van Keulen, A. (author)

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...

journal article 2018

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Current and future trends in topology optimization for additive manufacturing

Liu, Jikai (author), Gaynor, Andrew T. (author), Chen, Shikui (author), Kang, Zhan (author), Suresh, Krishnan (author), Takezawa, Akihiro (author), Li, Lei (author), Kato, Junji (author), Tang, Jinyuan (author), Wang, C.C. (author), Cheng, Lin (author), Liang, Xuan (author), To, Albert. C. (author)

Manufacturing-oriented topology optimization has been extensively studied the past two decades, in particular for the conventional manufacturing methods, for example, machining and injection molding or casting. Both design and manufacturing engineers have benefited from these efforts because of the close-to-optimal and friendly-to-manufacture...

journal article 2018

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A simulator-assisted workshop for teaching chemostat cultivation in academic classes on microbial physiology

Hakkaart, X.D.V. (author), Pronk, J.T. (author), van Maris, A.J.A. (author)

Understanding microbial growth and metabolism is a key learning objective of microbiology and biotechnology courses, essential for understanding microbial ecology, microbial biotechnology and medical microbiology. Chemostat cultivation, a key research tool in microbial physiology that enables quantitative analysis of growth and metabolism under...

journal article 2017

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An additive manufacturing filter for topology optimization of print-ready designs

Langelaar, Matthijs (author)

Additive manufacturing (AM) offers exciting opportunities to manufacture parts of unprecedented complexity. Topology optimization is essential to fully exploit this capability. However, AM processes have specific limitations as well. When these are not considered during design optimization, modifications are generally needed in post...

journal article 2017

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Minimum compliance topology optimization of shell–infill composites for additive manufacturing

Wu, J. (author), Clausen, Anders (author), Sigmund, Ole (author)

Additively manufactured parts are often composed of two sub-structures, a solid shell forming their exterior and a porous infill occupying the interior. To account for this feature this paper presents a novel method for generating simultaneously optimized shell and infill in the context of minimum compliance topology optimization. Our method...

journal article 2017

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Topology optimization of part and support structures for additive manufacturing considering machining forces

Langelaar, Matthijs (author)

abstract 2017

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

Munro, D.P. (author), Ayas, C. (author), Langelaar, Matthijs (author), van Keulen, A. (author)

abstract 2017