A mold insert case study on topology optimized design for additive manufacturing

M. Sinico, Rajit Ranjan, M. Moshiri, Can Ayas, Matthijs Langelaar, A. Witvrouw, Fred van Keulen, W. Dewulf

Research output: Chapter in Book/Conference proceedings/Edited volumeConference contributionScientificpeer-review

2 Citations (Scopus)
103 Downloads (Pure)


The Additive Manufacturing (AM) of injection molding inserts has gained popularity during recent years primarily due to the reduced design-to-production time and form freedom offered by AM. In this paper, Topology Optimization (TO) is performed on a metallic mold insert which is to be produced by the Laser Powder Bed Fusion (LPBF) technique. First, a commercially available TO software is used, to minimize the mass of the component while ensuring adequate mechanical response under a prescribed loading condition. The commercial TO tool adopts geometry-based AM constraints and achieves a mass reduction of ~50 %. Furthermore, an in-house TO method has been developed which integrates a simplified AM process model within the standard TO algorithm for addressing the issue of local overheating during manufacturing. The two topology optimized designs are briefly compared, and the advantages of implementing manufacturing constraints into the TO algorithm are discussed.
Original languageEnglish
Title of host publicationSolid Freeform Fabrication 2019
Subtitle of host publicationProceedings of the 30th Annual International Solid Freeform Fabrication Symposium - An Additive Manufacturing Conference
Place of PublicationAustin, USA
PublisherUniversity of Texas
Publication statusPublished - 2019
Event30th Annual International Solid Freeform Fabrication Symposium: An Additive Manufacturing Conference - Austin, United States
Duration: 12 Aug 201914 Aug 2019


Conference30th Annual International Solid Freeform Fabrication Symposium
Country/TerritoryUnited States


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