Integrated component-support topology optimization for additive manufacturing with post-machining

Abstract

Purpose \n \n \n \n \nThe purpose of this paper is to communicate a method to perform simultaneous topology optimization of component and support structures considering typical metal additive manufacturing (AM) restrictions and post-print machining requirements. \n \n \n \n \nDesign/methodology/approach \n \n \n \n \nAn integrated topology optimization is proposed using two density fields: one describing the design and another defining the support layout. Using a simplified AM process model, critical overhang angle restrictions are imposed on the design. Through additional load cases and constraints, sufficient stiffness against subtractive machining loads is enforced. In addition, a way to handle non-design regions in an AM setting is introduced. \n \n \n \n \nFindings \n \n \n \n \nThe proposed approach is found to be effective in producing printable optimized geometries with adequate stiffness against machining loads. It is shown that post-machining requirements can affect optimal support structure layout. \n \n \n \n \nResearch limitations/implications \n \n \n \n \nThis study uses a simplified AM process model based on geometrical characteristics. A challenge remains to integrate more detailed physical AM process models to have direct control of stress, distortion and overheating. \n \n \n \n \nPractical implications \n \n \n \n \nThe presented method can accelerate and enhance the design of high performance parts for AM. The consideration of post-print aspects is expected to reduce the need for design adjustments after optimization. \n \n \n \n \nOriginality/value \n \n \n \n \nThe developed method is the first to combine AM printability and machining loads in a single topology optimization process. The formulation is general and can be applied to a wide range of performance and manufacturability requirements.