Topology optimization with additive manufacturing consideration for vehicle load path development

Abstract

Topology optimization has been widely studied and implemented as a powerful conceptual design tool in various engineering applications. However, the result from topology optimization has posed an implementation challenge to engineers because of the complexity of converting obtained solution into computer-aided design data and then fabricating it into real parts. Over the past few years, the advanced additive manufacturing technology with new materials and higher resolution output capabilities has opened numerous opportunities to fill the gap between topology optimization and product application. In this study, an engineering procedure is presented for the conversion of topology optimization result to ready-to-print model for additive manufacturing. The steps of post-optimization handling are outlined, and the potential practical issues for the additive manufacturing implementation are discussed. A vehicle example for full frontal impact load path development by topology optimization with inertia relief approach is used to exhibit the employed additive manufacturing implementation process with a reduced-scale part build. The arising implementation issues and needs are examined for future advance of topology optimization and additive manufacturing integration development. Figure 7. Cleanup of the topology optimization result. (a) Details of selected interrupted and disconnected features in the initial design. (b) Design after modifications.Figure 8. Additive manufacturing build for reduced-scale vehicle.

A personalized mandibular implant with supporting and porous structures designed with topology optimization – a case study of canine

“…The results also showed that the part with comprehensive structures and architectures could be fabricated by additive manufacturing (Tao and Ming, 2016;Langelaar, 2016;Wu et al, 2017;Chuang et al, 2017). And, the SLM process is suitable for fabricating the personalized implant with customized external shape and complicated internal structures.…”

Improved fracture resistance of 3D-printed elastoplastic structures with respect to their topology and orientation of deposited layers

“…Currently, three-dimensional (3D)-printing technologies are revolutionizing the design and manufacturing of products in many engineering fields, including aerospace [1,2], biotechnology [3], civil engineering [4,5], and automotive engineering [6,7]. The advantages of these techniques include the possibility of considering new shapes that cannot be obtained directly with classical manufacturing processes.…”

Topology Optimization Considering Additive Manufacturing Constraints In An Industrial Context

“…Additive manufacturing also known as 3D printing has established itself as a form of potentially disruptive manufacturing technique over the recent years. This technique has shown its potential in a variety of industrial domains such as automotive [4,12], medical engineering [5,15], aerospace [3,13] etc. Additive manufacturing process follows a layer by layer build up process which gives an entirely different nature to this technique in comparison to classical methods of fabrication.…”