Topology optimization methods for additive manufacturing: a review

Abstract

Topology optimization is widely recognized for its ability to determine the best distribution of material in a structure to optimize its stiffness. This process often leads to creative configurations that produce complicated geometries challenging to construct using traditional techniques. Additive manufacturing has recently received a lot of interest from academics as well as industry. When compared to traditional methods, additive manufacturing or 3D printing offers considerable benefits (direct manufacture, time savings, fabrication of complex geometries, etc.). Recently, additive manufacturing techniques are increasingly being employed in industry to create complex components that cannot be produced using standard methods. The primary benefit of these techniques is the amount of creative flexibility they give designers. Additive manufacturing technology with higher resolution output capabilities has created a wealth of options for bridging the topology optimization and product application gap. This paper is a preliminary attempt to determine the key aspects of research on the integration of topology optimization and additive manufacturing, to outline topology optimization methods for these aspects with a review of various scientific and industry applications during the last years.

Reducing the Cost of 3D Metal Printing Using Selective Laser Melting (SLM) Technology in the Manufacture of a Drill Body by Reinforcing Thin-Walled Shell Forms with Metal-Polymers

“…When solving a topological optimization problem, the first step is to make sure that the original model subjected to the optimization procedure is able to withstand workloads and has the necessary safety margin [39][40][41][42]. The margin of safety of the original model indicates that there is the ability for optimization in the model.…”

“…For the topological optimization of the digital solid model, in order to develop curved cooling channels and create an internal structural frame and internal cavities, the Altair Inspire 2022.1.1 software was used, as well as Kompas3D V20.0.0.3002. Topological optimization methods are described in [39][40][41][42]. Topological optimization allows us to perform a strength calculation of a digital model in order to identify those areas of the model material through which payloads are transferred from the fastening points to the actuating surfaces.…”

Adaptive Variable Design Algorithm for Improving Topology Optimization in Additive Manufacturing

“…These tools have been tested and applied to real-world components in some instances. More recent studies and reviews evidence a trend to use and develop this method for future applications in the world of part design [24][25][26][27][28][29][30] The paper conducts a comparative analysis on the structural optimization of a real part using four commercial software codes (PTC Creo Parametric 6.0.1.0, Altair HyperMesh 2023.1, Solidworks 2023, and Ansys Workbench 2023R1) and a self-implemented MATLAB code. The aim is to demonstrate the benefits of understanding and applying the core principles of the topology optimization process over the use of popular solvers, like Tosca, OptiStruct, Ansys, and PTC.…”