One of the challenging issues in additive manufacturing (AM) oriented topology optimization is how to design structures that are self-supportive in a manufacture process without introducing additional supporting materials. In the present contribution, it is intended to resolve this problem under an explicit topology optimization framework where optimal structural topology can be found by optimizing a set of explicit geometry parameters. Two solution approaches established based on the Moving Morphable Components (MMC) and Moving Morphable Voids (MMV) frameworks, respectively, are proposed and some theoretical issues associated with AM oriented topology optimization are also analyzed. Numerical examples provided demonstrate the effectiveness of the proposed methods.

Traditional topology optimization is usually carried out with approaches where structural boundaries are represented in an implicit way. The aim of the present paper is to develop a topology optimization framework where both the shape and topology of a structure can be obtained simultaneously through an explicit boundary description and evolution. To this end, B-spline curves are used to describe the boundaries of moving morphable components (MMCs) or moving morphable voids (MMVs) in the structure and some special techniques are developed to preserve the smoothness of the structural boundary when topological change occurs. Numerical examples show that optimal designs with smooth structural boundaries can be obtained successfully with the use of the proposed approach.

Three dimensional (3D) topology optimization problems always involve huge numbers of Degrees of Freedom (DOFs) in finite element analysis (FEA) and design variables in numerical optimization, respectively. This will inevitably lead to large computational efforts in the solution process. In the present paper, an efficient and explicit topology optimization approach which can reduce not only the number of design variables but also the number of degrees of freedom in FEA is proposed based on the Moving Morphable Voids (MMVs) solution framework. This is achieved by introducing a set of geometry parameters (e.g., control points of B-spline surfaces) to describe the boundary of a structure explicitly and removing the unnecessary DOFs from the FE model at every step of numerical optimization. Numerical examples demonstrate that the proposed approach does can overcome the bottleneck problems associated with a 3D topology optimization problem in a straightforward way and enhance the solution efficiency significantly.

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Summary With the fast development of additive manufacturing technology, topology optimization involving multiple materials has received ever increasing attention. Traditionally, this kind of optimization problem is solved within the implicit solution framework by using the Solid Isotropic Material with Penalization or level set method. This treatment, however, will inevitably lead to a large number of design variables especially when many types of materials are involved and 3‐dimensional (3D) problems are considered. This is because for each type of material, a corresponding density field/level function defined on the entire design domain must be introduced to describe its distribution. In the present paper, a novel approach for topology optimization with multiple materials is established based on the Moving Morphable Component framework. With use of this approach, topology optimization problems with multiple materials can be solved with much less numbers of design variables and degrees of freedom. Numerical examples provided demonstrate the effectiveness of the proposed approach.