Related papers: Topology optimization considering the distortion i…
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…
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…
A topology optimization formulation including a model of the layer-by-layer additive manufacturing (AM) process is considered. Defined as a multi-objective minimization problem, the formulation accounts for the performance and cost of both…
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…
A support structure is required to successfully create structural parts in the powder bed fusion process for additive manufacturing. In this study, we present the topology optimization of a support structure that improves the heat…
Powder bed fusion is a widely used additive manufacturing (AM) process for producing complex, small-batch parts that are impractical to manufacture using conventional methods. However, its broader adoption is hindered by process-induced…
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…
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 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…
Topology optimization produces designs with intricate geometries and complex topologies that require advanced manufacturing techniques such as additive manufacturing (AM). However, insufficient consideration of manufacturability during the…
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…
Numerical simulations of a complete laser powder bed fusion (LPBF) additive manufacturing (AM) process are extremely challenging or even impossible to achieve without a radical model reduction of the complex physical phenomena occurring…
Additive Manufacturing (AM) processes intended for large scale components deposit large volumes of material to shorten process duration. This reduces the resolution of the AM process, which is typically defined by the size of the deposition…
Additive manufacturing (AM) enables enormous freedom for design of complex structures. However, the process-dependent limitations that result in discrepancies between as-designed and as-manufactured shapes are not fully understood. The…
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…
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…
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…
Additive manufacturing (AM) techniques hold promise but face significant challenges in process planning and optimization. The large temporal and spatial variations in temperature that can occur in layer-wise AM lead to thermal excursions,…
In this paper, we propose PATO-a producibility-aware topology optimization (TO) framework to help efficiently explore the design space of components fabricated using metal additive manufacturing (AM), while ensuring manufacturability with…
Reverse engineering can be used to derive a 3D model of an existing physical part when such a model is not readily available. For parts that will be fabricated with subtractive and formative manufacturing processes, existing reverse…