A survey of design methods for material extrusion polymer 3D printing

Huang, Jiaqi; Chen, Qian; Jiang, Hao; Zou, Bin; Li, Lei; Liu, Ji‐Kai; Yu, Huangchao

doi:10.1080/17452759.2019.1708027

Cited by 74 publications

(30 citation statements)

References 131 publications

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“…Because of the anisotropic properties induced by the layered manufacturing process in AM, a great number of studies have been dedicated to studying the influence of anisotropic behaviors on design activities [41][42][43]. The relevant literature in this field is reviewed in this section.…”

Section: Literature Reviewmentioning

confidence: 99%

“…This type of tool path planning is made possible by employing the level set function for structural representation due to the signed distance feature [49]. However, the design space is severely reduced because the raster directions have to follow the shape of the boundary profile [43]. To avoid this issue, the multipatch tool path planning will be introduced in this paper.…”

Section: Literature Reviewmentioning

confidence: 99%

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Topology Optimization for Multipatch Fused Deposition Modeling 3D Printing

Hong

Cao

2020

Applied Sciences

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This paper presents a hybrid topology optimization method for multipatch fused deposition modeling (FDM) 3D printing to address the process-induced material anisotropy. The ‘multipatch’ concept consists of each printing layer disintegrated into multiple patches with different zigzag-type filament deposition directions. The level set method was employed to represent and track the layer shape evolution; discrete material optimization (DMO) model was adopted to realize the material property interpolation among the patches. With this set-up, a concurrent optimization problem was formulated to simultaneously optimize the topological structure of the printing layer, the multipatch distribution, and the corresponding deposition directions. An asynchronous starting strategy is proposed to prevent the local minimum solutions caused by the concurrent optimization scheme. Several numerical examples were investigated to verify the effectiveness of the proposed method, while satisfactory optimization results have been derived.

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Section: Literature Reviewmentioning

confidence: 99%

Section: Literature Reviewmentioning

confidence: 99%

Topology Optimization for Multipatch Fused Deposition Modeling 3D Printing

Hong

Cao

2020

Applied Sciences

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“…However, approaches based on lightened structures also offer specific opportunities in different fields, such as load-bearing structures used in coated implants [ 34 ] or the manufacturing of personalized orthosis adapted to the anatomy of the patient and with advantages in terms of weight, ventilation and hygiene advantages [ 35 ]. Therefore, this context offers a wide range of design possibilities and even allows the definition of specific criteria or design strategies to additive manufacturing contexts [ 36 , 37 , 38 , 39 ].…”

Section: Introductionmentioning

confidence: 99%

Integration of Additive Manufacturing, Parametric Design, and Optimization of Parts Obtained by Fused Deposition Modeling (FDM). A Methodological Approach

2020

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The use of current computer tools in both manufacturing and design stages breaks with the traditional conception of productive process, including successive stages of projection, representation, and manufacturing. Designs can be programmed as problems to be solved by using computational tools based on complex algorithms to optimize and produce more effective solutions. Additive manufacturing technologies enhance these possibilities by providing great geometric freedom to the materialization phase. This work presents a design methodology for the optimization of parts produced by additive manufacturing and explores the synergies between additive manufacturing, parametric design, and optimization processes to guide their integration into the proposed methodology. By using Grasshopper, a visual programming application, a continuous data flow for parts optimization is defined. Parametric design tools support the structural optimization of the general geometry, the infill, and the shell structure to obtain lightweight designs. Thus, the final shapes are obtained as a result of the optimization process which starts from basic geometries, not from an initial design. The infill does not correspond to pre-established patterns, and its elements are sized in a non-uniform manner throughout the piece to respond to different local loads. Mass customization and Fused Deposition Modeling (FDM) systems represent contexts of special potential for this methodology.

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“…AM breaks the restrictions between design and manufacturing and makes the greatest design freedom possible. Design for additive manufacturing (DfAM) has therefore attracted a great deal of attention [2,3].…”

Section: Introductionmentioning

confidence: 99%

“…Topology optimization has been widely treated as the main computational design method for AM [ 1 , 2 , 3 , 4 ], because it explores a large design space and successfully applies in different physical disciplines [ 5 , 6 , 7 , 8 ]. Diverse topology optimization methods have been proposed, including the homogenization method [ 9 , 10 ], solid isotropic material with penalization (SIMP) [ 11 , 12 ], evolutionary structural optimization (ESO) [ 13 ], the level set method (LSM) [ 14 , 15 ], the moving morphable component (MMC) method [ 16 ], and some others.…”

Section: Introductionmentioning

confidence: 99%

Topology Optimization for FDM Parts Considering the Hybrid Deposition Path Pattern

Huang

Liu

et al. 2020

Micromachines

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Based on a solid orthotropic material with penalization (SOMP) and a double smoothing and projection (DSP) approach, this work proposes a methodology to find an optimal structure design which takes the hybrid deposition path (HDP) pattern and the anisotropic material properties into consideration. The optimized structure consists of a boundary layer and a substrate. The substrate domain is assumed to be filled with unidirectional zig-zag deposition paths and customized infill patterns, while the boundary is made by the contour offset deposition paths. This HDP is the most commonly employed path pattern for the fused deposition modeling (FDM) process. A critical derivative of the sensitivity analysis is presented in this paper, which ensures the optimality of the final design solutions. The effectiveness of the proposed method is validated through several 2D numerical examples.

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A survey of design methods for material extrusion polymer 3D printing

Cited by 74 publications

References 131 publications

Topology Optimization for Multipatch Fused Deposition Modeling 3D Printing

Topology Optimization for Multipatch Fused Deposition Modeling 3D Printing

Integration of Additive Manufacturing, Parametric Design, and Optimization of Parts Obtained by Fused Deposition Modeling (FDM). A Methodological Approach

Topology Optimization for FDM Parts Considering the Hybrid Deposition Path Pattern

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