Topology optimization of 3D self-supporting structures for additive manufacturing

Langelaar, Matthijs

doi:10.1016/j.addma.2016.06.010

Topology optimization of 3D self-supporting structures for additive manufacturing

Title

Topology optimization of 3D self-supporting structures for additive manufacturing

Author

Langelaar, Matthijs (TU Delft Computational Design and Mechanics)

Date

2016

Abstract

The potential of topology optimization to amplify the benefits of additive manufacturing (AM), by fully exploiting the vast design space that AM allows, is widely recognized. However, existing topology optimization approaches do not consider AM-specific limitations during the design process, resulting in designs that are not self-supporting. This leads to additional effort and costs in post-processing and use of sacrificial support structures. To overcome this difficulty, this paper presents a topology optimization formulation that includes a simplified AM fabrication model implemented as a layerwise filtering procedure. Unprintable geometries are effectively excluded from the design space, resulting in fully self-supporting optimized designs. The procedure is demonstrated on numerical examples involving compliance minimization, eigenfrequency maximization and compliant mechanism design. Despite the applied restrictions, in suitable orientations fully printable AM-restrained designs matched the performance of reference designs obtained by conventional topology optimization.

Subject

Topology optimization
Additive manufacturing
Overhang angle
Self-supporting designs
Manufacturing restrictions

To reference this document use:

http://resolver.tudelft.nl/uuid:c49bb07e-bf70-48fd-96b8-f07d7c0c26f5

DOI

https://doi.org/10.1016/j.addma.2016.06.010

Embargo date

2018-06-09

ISSN

2214-8604

Source

Additive Manufacturing, 12 (Part A), 60-70