Topology Optimization for FDM Parts Considering the Hybrid Deposition Path Pattern

Abstract

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.

Enhancing the Structural Strength for Injection Molding Tooling With Conformal Cooling Channels Using ANSYS Software

“…However, the layout of conformal cooling channels was not optimized in this study. Thus, optimization of the layout of conformal cooling channels using design of experiment method [47][48][49] or topology optimization method [50][51][52][53] is an important research issue.…”

Support Structure Topology Optimization Considering the Residual Distortion for Laser Powder Bed Fusion Metal Additive Manufacturing

“…As a flexible structural optimization method with large degrees of freedom, topology optimization allows the structural size, shape and topology to simultaneously evolve, thus providing higher-performing structural solutions than those obtained from the conventional design methods [6][7] [8]. In practice, topologically optimized designs are unfriendly to AM and a number of specialized topology optimization methods addressing AM manufacturable issues have been proposed, such as the length scale control [9][10] [11] [12][13] [14], enclosed void issue [15] [16], connectivity constraint [17] [18], considering the printing path effect [19] [20][21] [22], residual stress/distortion control [23] [24][25] [26], as well as the self-support issues [27] [28] [29] [30][31] [32] [33][34] [35] [36][37] [38][39] [40].…”

Weld Strength of Friction Welding of Dissimilar Polymer Rods Fabricated by Fused Deposition Modeling

“…Fuse deposition modeling (FDM) is a common material extrusion (MEX) process. FDM [17,18] has been widely utilized for the production of prototypes, which is a process of fabricating physical models using materials such as polylactic acid (PLA) [19], polyamide (PA) [20], polycarbonate (PC) [21], or acrylonitrile butadiene styrene (ABS) [22][23][24]. Bernal et al [25] utilized impulse excitation technique to obtain an effective isotropic Young's modulus of FDM-printed thermoplastic materials used in topology optimization design.…”