High-precision motion system design by topology optimization considering additive manufacturing

In the design process of high-precision motion stages, the dynamic behavior is of paramount importance. Manual design of such a stage is a time-consuming process, involving many iterations between engineers responsible for mechanics, dynamics and control. By using topology optimization in combination with additive manufacturing, post-processing using traditional machining and parts assembly, it is possible to arrive at an optimal design in an automated manner. The printing, machining, and assembly steps are incorporated in the optimization in order to directly arrive at a manufacturable design. With a motion stage demonstrator optimized for maximum eigenfrequencies, it is shown that combining additive manufacturing and topology optimization at industry-relevant design precision is within reach and can be applied to high-performance motion systems.