Topology optimization for additive manufacturing with controllable support structure costs

Matthijs Langelaar

Topology optimization for additive manufacturing with controllable support structure costs

Computational Design and Mechanics

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

19 Citations (Scopus)

108 Downloads (Pure)

Abstract

Advances in additive manufacturing (AM) allow economical production of components with unprecedented geometric complexity. This offers exciting opportunities for innovative designs, and particularly topology optimization has been identified as a key technique to fully exploit the capabilities of AM. However, also AM involves manufacturing restrictions, such as limitations on the inclination of overhanging parts. To deal with this problem, either sacrificial supporting structures can be added during the process, or only self-supporting designs can be considered. Both approaches have disadvantages, as support structures add material and post-processing costs, while demanding exclusively self-supporting designs may impose strong restrictions on achievable performance. With current methods, designers are limited to a choice between these two extremes. To open up a wider range of designs, this paper presents and demonstrates a topology optimization formulation that allows the designer to find trade-off solutions between design performance and support structure costs, considering both printing and removal costs

Original language	English
Title of host publication	Proceedings of the 7th European Congress on Computational Methods in Applied Sciences and Engineering
Subtitle of host publication	ECCOMAS Congress 2016
Editors	M. Papadrakakis, V. Papadopoulos, G. Stefanou, V. Plevris
Publisher	National Technical University of Athens (NTUA), Greece
Pages	3689-3699
ISBN (Print)	978-618-82844-0-1
Publication status	Published - 2016
Event	7th European Congress on Computational Methods in Applied Sciences and Engineering - Crete, Greece Duration: 5 Jun 2016 → 10 Jun 2016 Conference number: 7 https://www.eccomas2016.org/

Conference

Conference	7th European Congress on Computational Methods in Applied Sciences and Engineering
Abbreviated title	ECCOMAS Congress 2016
Country/Territory	Greece
City	Crete
Period	5/06/16 → 10/06/16
Internet address	https://www.eccomas2016.org/

Keywords

Topology optimization
additive manufacturing
overhang angle
support structures
self-supporting designs
manufacturing restrictions

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Langelaar eccomas_2016_vol_2Final published version, 3.83 MB

Cite this

Langelaar, M. (2016). Topology optimization for additive manufacturing with controllable support structure costs. In M. Papadrakakis, V. Papadopoulos, G. Stefanou, & V. Plevris (Eds.), Proceedings of the 7th European Congress on Computational Methods in Applied Sciences and Engineering: ECCOMAS Congress 2016 (pp. 3689-3699). National Technical University of Athens (NTUA), Greece.

Langelaar, Matthijs. / Topology optimization for additive manufacturing with controllable support structure costs. Proceedings of the 7th European Congress on Computational Methods in Applied Sciences and Engineering: ECCOMAS Congress 2016. editor / M. Papadrakakis ; V. Papadopoulos ; G. Stefanou ; V. Plevris. National Technical University of Athens (NTUA), Greece, 2016. pp. 3689-3699

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abstract = "Advances in additive manufacturing (AM) allow economical production of components with unprecedented geometric complexity. This offers exciting opportunities for innovative designs, and particularly topology optimization has been identified as a key technique to fully exploit the capabilities of AM. However, also AM involves manufacturing restrictions, such as limitations on the inclination of overhanging parts. To deal with this problem, either sacrificial supporting structures can be added during the process, or only self-supporting designs can be considered. Both approaches have disadvantages, as support structures add material and post-processing costs, while demanding exclusively self-supporting designs may impose strong restrictions on achievable performance. With current methods, designers are limited to a choice between these two extremes. To open up a wider range of designs, this paper presents and demonstrates a topology optimization formulation that allows the designer to find trade-off solutions between design performance and support structure costs, considering both printing and removal costs",

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publisher = "National Technical University of Athens (NTUA), Greece",

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Langelaar, M 2016, Topology optimization for additive manufacturing with controllable support structure costs. in M Papadrakakis, V Papadopoulos, G Stefanou & V Plevris (eds), Proceedings of the 7th European Congress on Computational Methods in Applied Sciences and Engineering: ECCOMAS Congress 2016. National Technical University of Athens (NTUA), Greece, pp. 3689-3699, 7th European Congress on Computational Methods in Applied Sciences and Engineering, Crete, Greece, 5/06/16.

Topology optimization for additive manufacturing with controllable support structure costs. / Langelaar, Matthijs.
Proceedings of the 7th European Congress on Computational Methods in Applied Sciences and Engineering: ECCOMAS Congress 2016. ed. / M. Papadrakakis; V. Papadopoulos; G. Stefanou; V. Plevris. National Technical University of Athens (NTUA), Greece, 2016. p. 3689-3699.

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

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Langelaar M. Topology optimization for additive manufacturing with controllable support structure costs. In Papadrakakis M, Papadopoulos V, Stefanou G, Plevris V, editors, Proceedings of the 7th European Congress on Computational Methods in Applied Sciences and Engineering: ECCOMAS Congress 2016. National Technical University of Athens (NTUA), Greece. 2016. p. 3689-3699

Topology optimization for additive manufacturing with controllable support structure costs

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