Topology optimization with nozzle size restrictions for material extrusion-type additive manufacturing
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RESEARCH PAPER
Topology optimization with nozzle size restrictions for material extrusion-type additive manufacturing Josephine V. Carstensen1 Received: 12 February 2020 / Revised: 9 April 2020 / Accepted: 23 April 2020 © Springer-Verlag GmbH Germany, part of Springer Nature 2020
Abstract Topology optimization that is tailored to additive manufacturing constraints and possibilities is an important area of research with direct implications on solution manufacturability. This paper focuses on implementing the nozzle size constraint that is associated with most material extrusion-type additive manufacturing processes, such as fused filament fabrication and concrete 3D printing. The constraint is especially important for manufacturability in situations where the size of used nozzle is large in comparison with the size of the design domain. This paper suggests a new projection-based algorithm that embeds material extrusion-type primitives into the projection methodology used for material distribution approaches to topology optimization. Projection-based algorithms for continuum topology optimization have received considerable attention in recent years due to their ability to improve manufacturability in a flexible and computationally efficient manner. A formulation for single-directional primitives is presented and extended to allow the use of two-directional primitives that can simulate a more realistic nozzle movement. The proposed algorithms are demonstrated on 2D benchmark problems and are shown to satisfy the imposed nozzle size restrictions. Keywords Topology optimization · Manufacturability · Projection · Additive manufacturing · Material extrusion · 3D printing
1 Introduction Recent decades have seen a rapid development in all additive manufacturing technologies, including material extrusion-type 3D printing. This has raised the need for new design methods that can leverage the new, increasingly complex manufacturing possibilities (Thompson et al. 2016). Topology optimization is often suggested as a design-foradditive manufacturing method since it has potential to generate new high-performing design solutions. It is a freeform design approach that does not require a pre-conceived notion of the final layout, and the resulting solutions are often complex. Although the technological developments of manufacturing processes have created a new fabrication
Responsible Editor: YoonYoung Kim Josephine V. Carstensen
[email protected] 1
Department of Civil and Environmental Engineering, Massachusetts Institute of Technology, 77 Massachusetts Ave, Cambridge MA, 02139, USA
paradigm, there are still associated limitations that must be considered during the design process (Liu et al. 2018). Therefore, this work seeks to implicitly embed the nozzle size constraint associated with material extrusion-type additive manufacturing processes such as fused filament fabrication (FFF) (or fused deposition modeling (FDM)) and concrete 3D printing. Recently, there has been a large interest in developing topology optimization framewor
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