Design for additive manufacturing: 3D simultaneous topology and build orientation optimization
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RESEARCH PAPER
Design for additive manufacturing: 3D simultaneous topology and build orientation optimization Jack Olsen 1 & Il Yong Kim 2 Received: 8 December 2019 / Revised: 5 March 2020 / Accepted: 28 March 2020 # Springer-Verlag GmbH Germany, part of Springer Nature 2020
Abstract The primary driver for technological advancement in design methods is increasing part performance and reducing manufacturing cost. Design optimization tools, such as topology optimization, provide a mathematical approach to generate efficient and lightweight designs; however, integration of this design tool into industry has been hindered most notably by manufacturability. Innovative processes, such as additive manufacturing (AM), have significantly more design freedom than traditional manufacturing methods, providing a means to develop the complex designs produced by topology optimization. The layer-wise nature of AM leads to new design challenges such as the need for support material, influenced by part topology and build orientation. Previous works addressing approaches to limit support material often rely on the finite element discretization scheme, leading to a gap between solving academic and practical problems. This study presents an approach to simultaneously optimize part topology and build orientation with AM considerations. Utilizing the spatial density gradient in the topology optimization formulation, the dependence on the finite element discretization scheme is reduced. The proposed approach has the potential to significantly decrease support material, while having a minimal impact on structural performance. Both 2D and 3D academic test problems, as well as an aerospace industry example, demonstrate the proposed methodology is capable of generating high-quality designs. Keywords Additive manufacturing . Topology optimization . Support material . Supported surface . Build orientation . Design for additive manufacturing
1 Introduction Additive manufacturing (AM) is an umbrella term used to describe any process that adds material together to produce a final part. This manufacturing technology was formerly seen only as a rapid prototyping tool; however, the recognition of its ability to create complex designs has led to its use in a Responsible Editor: Xu Guo * Il Yong Kim [email protected] Jack Olsen [email protected] 1
Department of Mechanical and Materials Engineering, Queen’s University, Room 213, Jackson Hall, 5 Field Company Ln, Kingston, ON K7L 2N8, Canada
2
Department of Mechanical and Materials Engineering, Queen’s University, Room 305, McLaughlin Hall, Kingston, ON K7L 3N6, Canada
widespread range of applications. The evolution of this manufacturing process has included the use of multiple different material groups such as polymer, metal, and composite. AM technology is being pursued by various industries including aerospace, who are interested in high-performance, reliable, and lightweight designs. In 2018, the global additive manufacturing market was valued at US$ 8.44 billion and is expected to grow to US$
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