scholarly journals Topology optimization with additive manufacturing constraints

2021 ◽  
Author(s):  
Grzegorz Misiun
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Manufacturing Constraints

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.

Direct Solid Element Slicing in Topology Optimization for Additive Manufacturing

2019 ◽  
Author(s):  
Dylan Bender ◽  
Ahmad Barari
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Closed Loop ◽  
Element Model ◽  
Solid Model ◽  
Manufacturing Constraints ◽  
Manufacturing Process Planning ◽  
Almost All ◽  
The Finite Element Model ◽  
Direct Solid

Abstract The traditional input to almost all commercially available Additive Manufacturing (AM) systems is in STL (Standard Tessellation Language) format, which represents a solid model by its tessellated surfaces. This does not allow transferring the entire information of a solid model to the additive manufacturing preprocessing system. However, in some recent applications such as additive manufacturing preprocessing simulation, closed-loop of topology optimization and additive manufacturing process planning, and AM-based design optimization the full access to the solid model information is necessary. Slicing of the finite element model directly is introduced in this paper. The presented approach enables access to the entire solid model information during the AM preprocessing tasks with a focus on coupling the topology optimization in the design process with the actual manufacturing constraints.

scholarly journals Developing Topology Optimization with Additive Manufacturing Constraints in ANSYS®

2018 ◽  
Vol 51 (11) ◽  
pp. 1359-1364 ◽  
Author(s):  
Davin Jankovics ◽  
Hossein Gohari ◽  
Mohsen Tayefeh ◽  
Ahmad Barari
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Manufacturing Constraints

Gradient-Based Multi-Component Topology Optimization for Additive Manufacturing (MTO-A)

2017 ◽  
Author(s):  
Yuqing Zhou ◽  
Kazuhiro Saitou
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Simultaneous Optimization ◽  
Minimum Length ◽  
Manufacturing Constraints ◽  
Component Level ◽  
Component Size ◽  
Design Variables ◽  
Gradient Based ◽  
Minimum Length Scale

Topology optimization for additive manufacturing has been limited to the component-level designs with the component size smaller than the printer’s build volume. To enable the design of structures larger than the printer’s build volume, this paper presents a gradient-based multi-component topology optimization framework for structures assembled from components built by additive manufacturing. Constraints on component geometry for additive manufacturing are incorporated in the density-based topology optimization, with additional design variables specifying fractional component membership. For each component, constraints on build size, enclosed voids, overhangs, and the minimum length scale are imposed during the simultaneous optimization of overall base topology and component partitioning. The preliminary result on a minimum compliance structure shows promising advantages over the conventional monolithic topology optimization. Manufacturing constraints previously applied to monolithic topology optimization gain new interpretations when applied to multi-component assemblies, which can unlock richer design space for topology exploration.

scholarly journals Topology optimization of the tool holder produced with additive manufacturing

2021 ◽  
Vol 1199 (1) ◽  
pp. 012086
Author(s):  
M Stepanek ◽  
K Raz ◽  
Z Chval
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Production Technology ◽  
Weight Reduction ◽  
Laser Sintering ◽  
Topological Optimization ◽  
Manufacturing Constraints ◽  
Direct Metal Laser Sintering ◽  
Tool Holder

Abstract This paper deals with the topology optimizations of tool holder where three different mass targets were required. The holder was loaded with 499 N. Weight reduction of the tool holder placed in tool turret can positively affect the bearing durability. Easier manipulation with the holder is one of the results. In the process of the topological optimization manufacturing constraints, such as overhang prevention, self-supporting and material spreading were defined for needs of Direct Metal Laser Sintering production technology. Structural analyses of three obtained geometries were simulated for evaluation of the stiffness in three main directions of the tool holder. Finally, the weight and the stiffness of each individual geometry was compared and prepared for manufacturing.

Additive Manufacturing Constraints in Topology Optimization for Improved Manufacturability

2018 ◽  
Vol 140 (5) ◽  
Author(s):  
Kunal Mhapsekar ◽  
Matthew McConaha ◽  
Sam Anand
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Experimental Validation ◽  
Manufacturing Processes ◽  
Manufacturing Constraints ◽  
Powder Bed Fusion ◽  
Powder Bed ◽  
And Topology ◽  
Am Processes

Additive manufacturing (AM) provides tremendous advantage over conventional manufacturing processes in terms of creative freedom, and topology optimization (TO) can be deemed as a potential design approach to exploit this creative freedom. To integrate these technologies and to create topology optimized designs that can be easily manufactured using AM, manufacturing constraints need to be introduced within the TO process. In this research, two different approaches are proposed to integrate the constraints within the algorithm of density-based TO. Two AM constraints are developed to demonstrate these two approaches. These constraints address the minimization of number of thin features as well as minimization of volume of support structures in the optimized parts, which have been previously identified as potential concerns associated with AM processes such as powder bed fusion AM. Both the manufacturing constraints are validated with two case studies each, along with experimental validation. Another case study is presented, which shows the combined effect of the two constraints on the topology optimized part. Two metrics of manufacturability are also presented, which have been used to compare the design outputs of conventional and constrained TO.

Local Redesign for Additive Manufacturability of Compliant Mechanisms Using Topology Optimization

2021 ◽  
Author(s):  
Stijn Koppen ◽  
Emma Hoes ◽  
Matthijs Langelaar ◽  
Mary I. Frecker
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Compliant Mechanisms ◽  
Compliant Mechanism ◽  
Computational Effort ◽  
Manufacturing Constraints ◽  
Design For Additive Manufacturing ◽  
Computationally Efficient ◽  
Stress Levels ◽  
Overhang Angle

Abstract Compliant mechanisms are crucial components in current and future high-precision applications. Topology optimization and additive manufacturing offer freedom to design complex compliant mechanisms that were impossible to realize using conventional manufacturing. Design for additive manufacturing constraints, such as the maximum overhang angle and minimum feature size, tend to drastically decrease the performance of topology optimized compliant mechanisms. It is observed that, among others, design for additive manufacturing constraints are only dominant in the flexure regions. Flexures are most sensitive to manufacturing errors, experience the highest stress levels and removal of support material carries the highest risk of failure. It is crucial to impose these constraints on the flexure regions, while in others part of the compliant mechanism design, these constraints can be relaxed. We propose to first design the global compliant mechanism layout in the full domain without imposing any design for additive manufacturing constraints. Subsequently we redesign selected refined local redesign domains with design for additive manufacturing constraints, whilst simultaneously considering the mechanism performance. The method is applied to a single-input-multi-output compliant mechanism case study, limiting the maximum overhang angle, introducing manufacturing robustness and limiting the maximum stress levels of a selected refined redesign domain. The high resolution local redesigns are detailed and accurate, without a large additional computational effort or decrease in mechanism performance. Thereto, the method proves widely applicable, computationally efficient and effective in its purpose.

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