Multi-Material Topology Optimization for Additive Manufacturing

2015 ◽  
Author(s):  
Amir M. Mirzendehdel ◽  
Krishnan Suresh
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Optimization Methods ◽  
Optimal Designs ◽  
Element Analysis ◽  
First Order ◽  
Multiple Materials ◽  
Material Fabrication ◽  
Single Material ◽  
Order Element

Additive manufacturing (AM) and topology optimization strongly complement each other in that the complex and optimal designs created through the latter can directly be fabricated through AM, leading to reduced design and fabrication time. As AM expands into multi-material fabrication, there is a natural need for efficient multi-material topology optimization methods, where one must simultaneously optimize the topology, and the distribution of various materials within the topology. In this paper we generalize the single-material Pareto tracing method of topology optimization to multiple materials, and discuss its implementation using assembly-free finite element analysis, and first-order element-sensitivity. The effectiveness of the algorithm is demonstrated through illustrative examples.

Evolutionary Topology Optimization of Spatial Steel-Concrete Structures

2021 ◽  
Vol 62 (2) ◽  
pp. 102-112
Author(s):  
Yu Li ◽  
Yi Min Xie
Keyword(s):  
Topology Optimization ◽  
Composite Structures ◽  
Optimization Technique ◽  
Optimization Techniques ◽  
Principal Stresses ◽  
Element Analysis ◽  
Floor Systems ◽  
Beso Method ◽  
Multiple Materials ◽  
Single Material

Topology optimization techniques based on finite element analysis have been widely used in many fields, but most of the research and applications are based on single-material structures. Extended from the bi-directional evolutionary structural optimization (BESO) method, a new topology optimization technique for 3D structures made of multiple materials is presented in this paper. According to the sum of each element's principal stresses in the design domain, a material more suitable for this element would be assigned. Numerical examples of a steel- concrete cantilever, two different bridges and four floor systems are provided to demonstrate the effectiveness and practical value of the proposed method for the conceptual design of composite structures made of steel and concrete.

scholarly journals Data-Driven Additive Manufacturing Constraints for Topology Optimization

2018 ◽  
Author(s):  
Benjamin M. Weiss ◽  
Joshua M. Hamel ◽  
Mark A. Ganter ◽  
Duane W. Storti
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Optimal Designs ◽  
Data Driven ◽  
Constraint Function ◽  
Manufacturing Constraint ◽  
Gradient Based ◽  
Fixed Radius ◽  
Different Shapes ◽  
Moving Morphable Components

The topology optimization (TO) of structures to be produced using additive manufacturing (AM) is explored using a data-driven constraint function that predicts the minimum producible size of small features in different shapes and orientations. This shape- and orientation-dependent manufacturing constraint, derived from experimental data, is implemented within a TO framework using a modified version of the Moving Morphable Components (MMC) approach. Because the analytic constraint function is fully differentiable, gradient-based optimization can be used. The MMC approach is extended in this work to include a “bootstrapping” step, which provides initial component layouts to the MMC algorithm based on intermediate Solid Isotropic Material with Penalization (SIMP) topology optimization results. This “bootstrapping” approach improves convergence compared to reference MMC implementations. Results from two compliance design optimization example problems demonstrate the successful integration of the manufacturability constraint in the MMC approach, and the optimal designs produced show minor changes in topology and shape compared to designs produced using fixed-radius filters in the traditional SIMP approach. The use of this data-driven manufacturability constraint makes it possible to take better advantage of the achievable complexity in additive manufacturing processes, while resulting in typical penalties to the design objective function of around only 2% when compared to the unconstrained case.

Synergy between topology optimization and additive manufacturing in the automotive field

2020 ◽  
pp. 095440542094920 ◽  
Author(s):  
S Mantovani ◽  
SG Barbieri ◽  
M Giacopini ◽  
A Croce ◽  
A Sola ◽  
...  
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Holistic Approach ◽  
Numerical Control ◽  
Structural Constraints ◽  
Element Analysis ◽  
Design Guideline ◽  
Numerical Control Machining ◽  
Optimization Constraints ◽  
Reference Component

This article purposes on developing and on re-interpreting the numerical results of a topology optimization for a structural component built via additive manufacturing. A critical appraisal of the optimization results is presented by modeling the feasible component with a holistic approach that merges structural and manufacturing requirements. The procedure is expected to provide a design guideline for similar applications of practical relevance, toward an increase of the right-first-time parts that is required to bring additive manufacturing to its full competitiveness. Topology optimization of a steering upright for a Formula SAE racing car was performed by targeting weight minimization while complying with severe structural constraints, like global and local stiffness performance. Cornering, bumping and braking vehicle conditions were considered. The optimization constraints were evaluated via finite element analysis on a reference component, where the loading conditions were retrieved from telemetry data. The reference part was manufactured by computer numerical control machining from a solid aluminum block. Spurred by the interpretation of the topology optimization predictions, a new upright geometry was designed and validated by calculating its stress field and the possible occurrence of Euler buckling. The new upright was 9% lighter than the reference component. The new geometry was analyzed according to Design for Additive Manufacturing principles to choose the orientation on the build platform and the supports’ location and geometry. The part was successfully manufactured and proved consistent with the application.

Incorporating Manufacturing Constraints in Topology Optimization Methods: A Survey

2017 ◽  
Author(s):  
Alok Sutradhar ◽  
Jaejong Park ◽  
Payam Haghighi ◽  
Jacob Kresslein ◽  
Duane Detwiler ◽  
...  
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Optimization Methods ◽  
Manufacturing Processes ◽  
Complex Geometries ◽  
Manufacturing Constraints ◽  
Post Processing ◽  
Optimization Framework ◽  
Manufacturing Methods ◽  
Traditional Manufacturing

Topology optimization provides optimized solutions with complex geometries which are often not suitable for direct manufacturing without further steps or post-processing by the designer. There has been a recent progression towards linking topology optimization with additive manufacturing, which is less restrictive than traditional manufacturing methods, but the technology is still in its infancy being costly, time-consuming, and energy inefficient. For applications in automotive or aerospace industries, the traditional manufacturing processes are still preferred and utilized to a far greater extent. Adding manufacturing constraints within the topology optimization framework eliminates the additional design steps of interpreting the topology optimization result and converting it to viable manufacturable parts. Furthermore, unintended but inevitable deviations that occur during manual conversion from the topology optimized result can be avoided. In this paper, we review recent advances to integrate (traditional) manufacturing constraints in the topology optimization process. The focus is on the methods that can create manufacturable and well-defined geometries. The survey will discuss the advantages, limitations, and related challenges of manufacturability in topology optimization.

scholarly journals Data-Driven Additive Manufacturing Constraints for Topology Optimization

2020 ◽  
Vol 143 (2) ◽  
Author(s):  
Benjamin M. Weiss ◽  
Joshua M. Hamel ◽  
Mark A. Ganter ◽  
Duane W. Storti
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Optimal Designs ◽  
Data Driven ◽  
Constraint Function ◽  
Manufacturing Constraint ◽  
Gradient Based ◽  
Fixed Radius ◽  
Different Shapes ◽  
Moving Morphable Components

Abstract The topology optimization (TO) of structures to be produced using additive manufacturing (AM) is explored using a data-driven constraint function that predicts the minimum producible size of small features in different shapes and orientations. This shape- and orientation-dependent manufacturing constraint, derived from experimental data, is implemented within a TO framework using a modified version of the moving morphable components (MMC) approach. Because the analytic constraint function is fully differentiable, gradient-based optimization can be used. The MMC approach is extended in this work to include a “bootstrapping” step, which provides initial component layouts to the MMC algorithm based on intermediate solid isotropic material with penalization (SIMP) topology optimization results. This “bootstrapping” approach improves convergence compared with reference MMC implementations. Results from two compliance design optimization example problems demonstrate the successful integration of the manufacturability constraint in the MMC approach, and the optimal designs produced show minor changes in topology and shape compared to designs produced using fixed-radius filters in the traditional SIMP approach. The use of this data-driven manufacturability constraint makes it possible to take better advantage of the achievable complexity in additive manufacturing processes, while resulting in typical penalties to the design objective function of around only 2% when compared with the unconstrained case.

Efficient Multi-Material Topology Optimization

2021 ◽  
pp. 275-292
Author(s):  
Amir M. Mirzendehdel ◽  
Krishnan Suresh
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Consumer Products ◽  
Simultaneous Optimization ◽  
Multiple Materials ◽  
Am Processes

This chapter focuses on generating optimized topologies using multiple materials. The interest in multi-material topology optimization (MMTO) stems from the well-recognized synergy between topology optimization (TO) and additive manufacturing (AM), where organic structures created through TO can be directly fabricated by a variety of AM processes. Given the rapidly increasing capabilities of AM, there is an opportunity to improve the performance of consumer products, biomedical, and aerospace components, through simultaneous optimization of topology and distribution of multiple materials.

scholarly journals Stiff isotropic lattices beyond the Maxwell criterion

2019 ◽  
Vol 5 (9) ◽  
pp. eaaw1937 ◽  
Author(s):  
Wen Chen ◽  
Seth Watts ◽  
Julie A. Jackson ◽  
William L. Smith ◽  
Daniel A. Tortorelli ◽  
...  
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Topology Optimization ◽  
Additive Manufacturing ◽  
De Novo ◽  
Mechanical Stiffness ◽  
Element Analysis ◽  
Anisotropic Lattices ◽  
Design Materials

Materials with a stochastic microstructure, like foams, typically exhibit low mechanical stiffness, whereas lattices with a designed microarchitecture often show notably improved stiffness. These periodic architected materials have previously been designed by rule, using the Maxwell criterion to ensure that their deformation is dominated by the stretching of their struts. Classical designs following this rule tend to be anisotropic, with stiffness depending on the load orientation, but recently, isotropic designs have been reported by superimposing complementary anisotropic lattices. We have designed stiff isotropic lattices de novo with topology optimization, an approach based on continuum finite element analysis. Here, we present results of experiments on these lattices, fabricated by additive manufacturing, that validate predictions of their performance and demonstrate that they are as efficient as those designed by rule, despite appearing to violate the Maxwell criterion. These findings highlight the enhanced potential of topology optimization to design materials with unprecedented properties.

scholarly journals Additive Manufacturing and Topology Optimization of Magnetic Materials for Electrical Machines—A Review

Energies ◽  
2021 ◽  
Vol 14 (2) ◽  
pp. 283
Author(s):  
Thang Pham ◽  
Patrick Kwon ◽  
Shanelle Foster
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Optimization Techniques ◽  
Electrical Machines ◽  
Electrical Machine ◽  
Magnetic Components ◽  
And Topology ◽  
Multiple Materials ◽  
Manufacturing Technologies ◽  
Conventional Optimization

Additive manufacturing has many advantages over traditional manufacturing methods and has been increasingly used in medical, aerospace, and automotive applications. The flexibility of additive manufacturing technologies to fabricate complex geometries from copper, polymer, and ferrous materials presents unique opportunities for new design concepts and improved machine power density without significantly increasing production and prototyping cost. Topology optimization investigates the optimal distribution of single or multiple materials within a defined design space, and can lead to unique geometries not realizable with conventional optimization techniques. As an enabling technology, additive manufacturing provides an opportunity for machine designers to overcome the current manufacturing limitation that inhibit adoption of topology optimization. Successful integration of additive manufacturing and topology optimization for fabricating magnetic components for electrical machines can enable new tools for electrical machine designers. This article presents a comprehensive review of the latest achievements in the application of additive manufacturing, topology optimization, and their integration for electrical machines and their magnetic components.

Multiple-Material Topology Optimization of Compliant Mechanisms Created Via PolyJet Three-Dimensional Printing

2014 ◽  
Vol 136 (6) ◽  
Author(s):  
Andrew T. Gaynor ◽  
Nicholas A. Meisel ◽  
Christopher B. Williams ◽  
James K. Guest
Keyword(s):  
Topology Optimization ◽  
Compliant Mechanisms ◽  
Three Dimensional ◽  
Three Dimensional Printing ◽  
Multiple Materials ◽  
Multiple Material ◽  
Phase Design ◽  
Dimensional Printing ◽  
Monolithic Structure ◽  
Single Material

Compliant mechanisms are able to transfer motion, force, and energy using a monolithic structure without discrete hinge elements. The geometric design freedoms and multimaterial capability offered by the PolyJet 3D printing process enables the fabrication of compliant mechanisms with optimized topology. The inclusion of multiple materials in the topology optimization process has the potential to eliminate the narrow, weak, hingelike sections that are often present in single-material compliant mechanisms and also allow for greater magnitude deflections. In this paper, the authors propose a design and fabrication process for the realization of 3-phase, multiple-material compliant mechanisms. The process is tested on a 2D compliant force inverter. Experimental and numerical performance of the resulting 3-phase inverter is compared against a standard 2-phase design.

scholarly journals Modal and Stress Analysis of Cellular Structures Produced with Additive Manufacturing by Finite Element Analysis (FEA)

2018 ◽  
Vol 1 (1) ◽  
pp. 263-272
Author(s):  
Bekir Yalçın ◽  
Berkay Ergene ◽  
Uçan Karakılınç
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Topology Optimization ◽  
Additive Manufacturing ◽  
Honeycomb Structure ◽  
Cellular Structures ◽  
Aircraft Industry ◽  
Element Analysis ◽  
Manufacturing Methods ◽  
High Level

Cellular structures such as regular/irregular honeycombs and re-entrants are known as lighter, high level flexibility and more efficient materials; these cellular structures have been mainly designed with topology optimization and obtained with new additive manufacturing methods for aircraft industry, automotive, medical, sports and leisure sectors. For this aim, the effect of cellular structures such as the honeycomb and re-entrant on vibration and stress-strain behaviors were determined under compression and vibration condition by finite elements analyses (FEA). In FEA, the re-entrant and honeycomb structures were modeled firstly and then the stress and displacement values for each structure were obtained. Secondly, vibration behaviors of these foam structures were estimated under determined boundary conditions. In conclusion, the effect of topology in foam structures on vibration and mechanical behaviour were exhibited in FEA results. The obtained stress results of FEA show that all stresses (?x, ?y, ?vm, ?xy) are lower on honeycomb structure than reentrant structure. Besides, natural frequency values (?1, ?2, ?3) and appearance of each structure were observed by using FEA.

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