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Metal additive manufacturing (AM) processes often fabricate a near-net shape that includes the as-designed part as well as the sacrificial support structures that need to be machined away by subtractive manufacturing (SM), for instance…
This paper presents a density-based topology optimization approach considering additive manufacturing limitations. The presented method considers the minimum size of parts, the minimum size of cavities, the inability of printing overhanging…
The paper presents a topology optimization approach that designs an optimal structure, called a self-supporting structure, which is ready to be fabricated via additive manufacturing without the usage of additional support structures. Such…
We introduce a method to analyze and modify a shape to make it manufacturable for a given additive manufacturing (AM) process. Different AM technologies, process parameters or materials introduce geometric constraints on what is…
This paper proposes a topology optimization method that considers the geometric constraint of no closed cavities to improve the effectiveness of additive manufacturing based on the fictitious physical model approach. First, the basic…
This paper proposes a self-support topology optimization method that considers distortion to improve the manufacturability of additive manufacturing. First, a self-support constraint is proposed that combines an overhang angle constraint…
In this paper, we present a topology optimization (TO) framework to enable automated design of mechanical components while ensuring the result can be manufactured using multi-axis machining. Although TO improves the part's performance, the…
Additive manufacturing is a free-form manufacturing technique in which parts are built in a layer-by-layer manner. Laser powder bed fusion is one of the popular techniques used to fabricate metal parts. However, it induces residual stress…
We propose a neural network-based approach to topology optimization that aims to reduce the use of support structures in additive manufacturing. Our approach uses a network architecture that allows the simultaneous determination of an…
In this paper a phase-field approach for structural topology optimization for a 3D-printing process which includes stress constraint and potentially multiple materials or multiscales is analyzed. First order necessary optimality conditions…
Additive manufacturing of metal parts involves phase transformations and high temperature gradients which lead to uneven thermal expansion and contraction, and, consequently, distortion of the fabricated components. The distortion has a…
Parts fabricated by additive manufacturing (AM) are often fabricated first as a near-net shape, a combination of intended nominal geometry and sacrificial support structures, which need to be removed in a subsequent post-processing stage…
Mechanical product engineering often must comply with manufacturing or geometric constraints related to the shaping process. Mechanical design hence should rely on robust and fast tools to explore complex shapes, typically for design for…
We present a level-set based topology optimization algorithm for design optimization problems involving an arbitrary number of different materials, where the evolution of a design is solely guided by topological derivatives. Our method can…
To facilitate widespread adoption of automated engineering design techniques, existing methods must become more efficient and generalizable. In the field of topology optimization, this requires the coupling of modern optimization methods…
In the current industry, the development of optimized mechanical components able to satisfy the customer requirements evolves quickly. Therefore, companies are asked for efficient solutions to improve their products in terms of stiffness…
Multiply connected freeform surface features are widely encountered in industrial components, where toolpath generation often suffers from discontinuities, sharp turns, non-uniform scallop heights, and incomplete boundary coverage. This…
In the industrial practice, additive manufacturing processes are often followed by post-processing operations such as subtractive machining, milling, etc. to achieve the desired surface quality and dimensional accuracy. Hence, a given part…
This paper introduces a simple formulation for topology optimization problems ensuring manufacturability by machining. The method distinguishes itself from existing methods by using the advection-diffusion equation with Robin boundary…
Integrating topology optimization and additive manufacturing (AM) technology can facilitate innovative product development. However, laser powder bed fusion, which is the predominant method in metal AM, can lead to issues such as residual…