Related papers: Reducing computational effort in topology optimiza…
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…
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…
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 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…
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…
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…
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…
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…
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,…
The ability to accurately quantify the performance an additively manufactured (AM) product is important for a widespread industry adoption of AM as the design is required to: (1) satisfy geometrical constraints, (2) satisfy structural…
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…
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 (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…
High-tech equipment critically relies on flexures for precise manipulation and measurement. Through elastic deformation, flexures offer extreme position repeatability within a limited range of motion in their degrees of freedom, while…
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…
The work explores a specific scenario for structural computational optimization based on the following elements: (a) a relaxed optimization setting considering the ersatz (bi-material) approximation, (b) a treatment based on a nonsmoothed…
Process optimization for metal additive manufacturing (AM) is crucial to ensure repeatability, control microstructure, and minimize defects. Despite efforts to address this via the traditional design of experiments and statistical process…
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…
We present an improved method for topology optimization with both adaptive mesh refinement and derefinement. Since the total volume fraction in topology optimization is usually modest, after a few initial iterations the domain of…
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…