Level set-based topology optimization with overhang constraint: Towards support-free additive manufacturing

Wang, Yaguang; Gao, Jincheng; Kang, Zhan

doi:10.1016/j.cma.2018.04.040

Cited by 109 publications

(38 citation statements)

References 37 publications

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“…Multiple works are available in the SIMP framework. In the level set framework we are working on an extension of the methods presented in [4] and [43]. The equivalent thermal load model can also be enriched by considering not only the deformations in the final shape ω, but also the deformations in the support structure S during the layer-by-layer manufacturing process.…”

Section: Discussionmentioning

confidence: 99%

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Support optimization in additive manufacturing for geometric and thermo-mechanical constraints

Allaire

Bihr

Bogosel

2020

Struct Multidisc Optim

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Section: Discussionmentioning

confidence: 99%

“…[33]). In the level set framework, the papers [4], [43] shows how to perform support-free optimization. An obvious extension of our work is to include in the optimization process a constraint limiting the overhang regions in the support structures.…”

Section: Shape and Topology Optimization -Pseudo Gravity Loadsmentioning

confidence: 99%

Support optimization in additive manufacturing for geometric and thermo-mechanical constraints

Allaire

Bihr

Bogosel

2020

Struct Multidisc Optim

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“…Several exciting works have focused on including the AM constraints, such as support structure elimination (through overhang elimination) in topology optimization routines and are included in references [28][29][30][31][32][33][34][35][36]. Additionally, Liu et al [37] recently presented a review paper on recent trends and future challenges that are associated with the incorporation of AM constraints and considerations into topology optimization algorithms.…”

Section: Topology Optimization For Additive Manufacturingmentioning

confidence: 99%

Topology Optimization for Additive Manufacturing as an Enabler for Light Weight Flight Hardware

Orme¹,

Madera²,

Gschweitl

et al. 2018

Designs

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Three case studies utilizing topology optimization and Additive Manufacturing for the development of space flight hardware are described. The Additive Manufacturing (AM) modality that was used in this work is powder bed laser based fusion. The case studies correspond to the redesign and manufacture of two heritage parts for a Surrey Satellite Technology LTD (SSTL) Technology Demonstrator Space Mission that are currently functioning in orbit (case studies 1 and 2), and a system of five components for the SpaceIL’s lunar launch vehicle planned for launch in the near future (case study 3). In each case, the nominal or heritage part has undergone topology optimization, incorporating the AM manufacturing constraints that include: minimization of support structures, ability to remove unsintered powder, and minimization of heat transfer jumps that will cause artifact warpage. To this end the topology optimization exercise must be coupled to the Additive Manufacturing build direction, and steps are incorporated to integrate the AM constraints. After design verification by successfully passing a Finite Element Analysis routine, the components have been fabricated and the AM artifacts and in-process testing coupons have undergone verification and qualification testing in order to deliver structural components that are suitable for their respective missions.

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“…Because the shape and topology are concurrently designed, topology optimization makes the greatest design freedom possible compared with shape-only or size-only optimization. However, there are new design rules and unique constraints induced by AM, which introduce new challenges such as support structure design/elimination [4][5][6][7][8][9][10], minimum component size constraints [11][12][13][14][15][16], directional material properties [17][18][19], topology design interpretation [20][21][22][23], variable-density cellular structure design [24][25][26][27][28], and many others [29,30]. Detailed reviews on these topics can be found in [2,31].…”

Section: Introductionmentioning

confidence: 99%

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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Level set-based topology optimization with overhang constraint: Towards support-free additive manufacturing

Cited by 109 publications

References 37 publications

Support optimization in additive manufacturing for geometric and thermo-mechanical constraints

Support optimization in additive manufacturing for geometric and thermo-mechanical constraints

Topology Optimization for Additive Manufacturing as an Enabler for Light Weight Flight Hardware

Topology Optimization for Multipatch Fused Deposition Modeling 3D Printing

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