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

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

Computational Design and Mechanics

Research output: Chapter in Book/Conference proceedings/Edited volume › Conference contribution › Scientific › peer-review

7 Citations (Scopus)

373 Downloads (Pure)

Abstract

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.
Introduction

Original language	English
Title of host publication	Solid Freeform Fabrication 2019
Subtitle of host publication	Proceedings of the 30th Annual International Solid Freeform Fabrication Symposium - An Additive Manufacturing Conference
Place of Publication	Austin, USA
Publisher	University of Texas
Pages	1921-1931
Publication status	Published - 2019
Event	30th Annual International Solid Freeform Fabrication Symposium: An Additive Manufacturing Conference - Austin, United States Duration: 12 Aug 2019 → 14 Aug 2019

Conference

Conference	30th Annual International Solid Freeform Fabrication Symposium
Country/Territory	United States
City	Austin
Period	12/08/19 → 14/08/19

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Sinico, M., Ranjan, R., Moshiri, M., Ayas, C., Langelaar, M., Witvrouw, A., van Keulen, F., & Dewulf, W. (2019). A mold insert case study on topology optimized design for additive manufacturing. In Solid Freeform Fabrication 2019: Proceedings of the 30th Annual International Solid Freeform Fabrication Symposium - An Additive Manufacturing Conference (pp. 1921-1931). University of Texas.

@inproceedings{486797f865574c77a145a512092a5106,

title = "A mold insert case study on topology optimized design for additive manufacturing",

abstract = "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.Introduction",

author = "M. Sinico and Rajit Ranjan and M. Moshiri and Can Ayas and Matthijs Langelaar and A. Witvrouw and {van Keulen}, Fred and W. Dewulf",

year = "2019",

language = "English",

pages = "1921--1931",

booktitle = "Solid Freeform Fabrication 2019",

publisher = "University of Texas",

note = "30th Annual International Solid Freeform Fabrication Symposium : An Additive Manufacturing Conference ; Conference date: 12-08-2019 Through 14-08-2019",

}

Sinico, M, Ranjan, R, Moshiri, M, Ayas, C , Langelaar, M, Witvrouw, A, van Keulen, F & Dewulf, W 2019, A mold insert case study on topology optimized design for additive manufacturing. in Solid Freeform Fabrication 2019: Proceedings of the 30th Annual International Solid Freeform Fabrication Symposium - An Additive Manufacturing Conference. University of Texas, Austin, USA, pp. 1921-1931, 30th Annual International Solid Freeform Fabrication Symposium, Austin, Texas, United States, 12/08/19.

A mold insert case study on topology optimized design for additive manufacturing. / Sinico, M.; Ranjan, Rajit; Moshiri, M. et al.
Solid Freeform Fabrication 2019: Proceedings of the 30th Annual International Solid Freeform Fabrication Symposium - An Additive Manufacturing Conference. Austin, USA: University of Texas, 2019. p. 1921-1931.

Research output: Chapter in Book/Conference proceedings/Edited volume › Conference contribution › Scientific › peer-review

TY - GEN

T1 - A mold insert case study on topology optimized design for additive manufacturing

AU - Sinico, M.

AU - Ranjan, Rajit

AU - Moshiri, M.

AU - Ayas, Can

AU - Langelaar, Matthijs

AU - Witvrouw, A.

AU - van Keulen, Fred

AU - Dewulf, W.

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N2 - 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.Introduction

AB - 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.Introduction

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M3 - Conference contribution

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EP - 1931

BT - Solid Freeform Fabrication 2019

PB - University of Texas

CY - Austin, USA

T2 - 30th Annual International Solid Freeform Fabrication Symposium

Y2 - 12 August 2019 through 14 August 2019

ER -

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

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