Topology optimization for additive manufacturing with controllable support structure costs

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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
Original languageEnglish
Title of host publicationProceedings of the 7th European Congress on Computational Methods in Applied Sciences and Engineering
Subtitle of host publicationECCOMAS Congress 2016
EditorsM. Papadrakakis, V. Papadopoulos, G. Stefanou, V. Plevris
PublisherNational Technical University of Athens (NTUA), Greece
Pages3689-3699
ISBN (Print)978-618-82844-0-1
Publication statusPublished - 2016
Event7th European Congress on Computational Methods in Applied Sciences and Engineering - Crete, Greece
Duration: 5 Jun 201610 Jun 2016
Conference number: 7
https://www.eccomas2016.org/

Conference

Conference7th European Congress on Computational Methods in Applied Sciences and Engineering
Abbreviated titleECCOMAS Congress 2016
CountryGreece
CityCrete
Period5/06/1610/06/16
Internet address

Keywords

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

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