An Optimization Workflow in Design for Additive Manufacturing

Abstract

Additive Manufacturing (AM) brought a revolution in parts design and production. It enables the possibility to obtain objects with complex geometries and to exploit structural optimization algorithms. Nevertheless, AM is far from being a mature technology and advances are still needed from different perspectives. Among these, the literature highlights the need of improving the frameworks that describe the design process and taking full advantage of the possibilities offered by AM. This work aims to propose a workflow for AM guiding the designer during the embodiment design phase, from the engineering requirements to the production of the final part. The main aspects are the optimization of the dimensions and the topology of the parts, to take into consideration functional and manufacturing requirements, and to validate the geometric model by computer-aided engineering software. Moreover, a case study dealing with the redesign of a piston rod is presented, in which the proposed workflow is adopted. Results show the effectiveness of the workflow when applied to cases in which structural optimization could bring an advantage in the design of a part and the pros and cons of the choices made during the design phases were highlighted.

Design for Additive Manufacturing: Methods and Tools

“…The authors proposed introducing TO, lattice infill optimisation, and generative design in earlier phases of the design process to maximise AM capabilities. Rosso et al [9] presented a DfAM workflow for embodiment design that combines Computer-Aided Design tools for the geometric modelling of the part and Computer-Aided Engineering tools for the optimisation and simulation phases. Their workflow considers the possibility of using size optimisation to obtain lattice structures with optimised beams and TO to obtain optimised organic shapes.…”

“…The overall DfAM strategy presented in Figure ?? is the lighthouse for other methods conceived for specific problems and products [1,[7][8][9][10][11].…”

Analysis of a Preliminary Design Approach for Conformal Lattice Structures

“…In the first subsection, the modeling methodology based on NURBS free-form deformation is described; in the second subsection, the size optimization method is briefly explained; in the third subsection, the validation methods through the beam linear structural analysis are described. The case study is a piston rod previously investigated by Rosso et al [54,55]. Figure 1 shows the main dimensions of the test case, highlighting in green the design space that was replaced by lattices.…”

A Review on Tailoring Stiffness in Compliant Systems, via Removing Material: Cellular Materials and Topology Optimization

“…In this regard, the stiffness of a compliant system can be modified through the implementation of specific cellular arrays in the flexible parts of the system. Tailoring stiffness has become more relevant with the emergence of modern manufacturing processes such as additive manufacturing techniques, capable of fabricating complex topologies and shapes [72][73][74][75]. Some studies [76][77][78] showed how the stiffness in beams can be customized by using different types of cellular structures while obtaining minimum weight designs.…”