Optimal topology for additive manufacture: A method for enabling additive manufacture of support-free optimal structures

Leary, Martin; Merli, Luigi; Torti, Federico; Mazur, Maciej; Brandt, Milan

doi:10.1016/j.matdes.2014.06.015

Cited by 315 publications

(182 citation statements)

References 32 publications

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“…All designs fully comply with the stated AM fabrication rules, and the influence of the 45 • overhang angle limitation can be recognized by various members that reach exactly this angle. Interestingly, similar patterns to those suggested by Leary et al (2014) to make existing designs printable by adding auxiliary structures, appear in these optimized designs directly due to the inclusion of the AM filter in the TO process. This is seen in particular in the S and N orientation.…”

Section: Influence Of Part Orientationsupporting

confidence: 65%

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An additive manufacturing filter for topology optimization of print-ready designs

Langelaar

2016

Struct Multidisc Optim

281

177

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Additive manufacturing (AM) offers exciting opportunities to manufacture parts of unprecedented complexity. Topology optimization is essential to fully exploit this capability. However, AM processes have specific limitations as well. When these are not considered during design optimization, modifications are generally needed in post-processing, which add costs and reduce the optimized performance. This paper presents a filter that incorporates the main characteristics of a generic AM process, and that can easily be included in conventional density-based topology optimization procedures. Use of this filter ensures that optimized designs comply with typical geometrical AM restrictions. Its performance is illustrated on compliance minimization problems, and a 2D Matlab implementation is provided.

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Section: Influence Of Part Orientationsupporting

confidence: 65%

“…Strano et al (2013), Vanek et al (2014), and Calignano (2014). Others have proposed a procedure to augment a previously optimized design with additional structures, to make it self-supporting (Leary et al 2014). The added structures are not sacrificial but become part of the design, which however alters the mass and performance of the original part.…”

mentioning

confidence: 99%

An additive manufacturing filter for topology optimization of print-ready designs

Langelaar

2016

Struct Multidisc Optim

281

177

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“…All of these strategies can increase the cost and time of production. For example, Leary et al [185] produced topology optimized cantilever beams with and without support structures using FDM (Fig. 42 and Fig.…”

Section: The Need For Support Structures During Productionmentioning

confidence: 99%

Design for Additive Manufacturing: Trends, opportunities, considerations, and constraints

et al. 2016

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The past few decades have seen substantial growth in Additive Manufacturing (AM) technologies. However, this growth has mainly been process-driven. The evolution of engineering design to take advantage of the possibilities afforded by AM and to manage the constraints associated with the technology has lagged behind. This paper presents the major opportunities, constraints, and economic considerations for Design for Additive Manufacturing. It explores issues related to design and redesign for direct and indirect AM production. It also highlights key industrial applications, outlines future challenges, and identifies promising directions for research and the exploitation of AM's full potential in industry.Design, Manufacturing, Additive Manufacturing

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“…A number of authors have proposed methods of design which completely avoid the need for support structures [3,8], but these techniques are in their infancy and have only been tested on 2D structures in the literature. Strano et al [16] optimised the support volume for 3D structures by calculating the support at every 5 • rotational angle about the x and y axes, subsequently choosing the lowest value.…”

Section: Introductionmentioning

confidence: 99%

Part orientation optimisation for the additive layer manufacture of metal components

Morgan

Cherry

Jonnalagadda

et al. 2016

Int J Adv Manuf Technol

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In a number of additive layer manufacturing processes, particularly for metals, additional support structure is required during the build process to act as scaffolding for overhanging features and to dissipate process heat. Such structures use valuable raw materials and their removal adds to post processing time. The objective of this study was to investigate whether a simple, single objective optimisation technique could be used to find the best orientation of the part, that would minimise the volume of support needed during the build. Not only reducing waste but potentially providing an effective and consistent approach for inexperienced users to orient components during manufacture. Software was developed using MatLab with an unconstrained optimisation algorithm implemented to search the different rotations of the part and identify the configuration with the least requirement for support volume. The algorithm was gradient based, and so multiple starting points were used to identify a global minimum. The efficacy of the algorithm is illustrated with three different case studies of increasing complexity. Additionally, the component of the final study was manufactured, which allowed a comparison between the algorithm's results and the orientations chosen by experienced operatives. In two of the three case studies, the software was able to find good solutions for the support volume minimisation. For the manufactured part, only one of the results matched the orientation chosen by the operators, the other was orientated in a similar way but the difference added significantly to the required support volume. Future developments of the software would benefit from incorporating the expertise of the manufacturing operative.

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Optimal topology for additive manufacture: A method for enabling additive manufacture of support-free optimal structures

Cited by 315 publications

References 32 publications

An additive manufacturing filter for topology optimization of print-ready designs

An additive manufacturing filter for topology optimization of print-ready designs

Design for Additive Manufacturing: Trends, opportunities, considerations, and constraints

Part orientation optimisation for the additive layer manufacture of metal components

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