Article
Materials Science, Multidisciplinary
Rossana R. Fernandes, Ali Y. Tamijani
Summary: This paper presents an experimentally validated framework for performing topology and orientation optimization of lattice structures subject to stress constraints. Effective stiffnesses and yield stresses of a unit cell are obtained using numerical homogenization and implemented via macrostructure topology optimization to improve lattice structure stiffness.
MATERIALS & DESIGN
(2021)
Article
Engineering, Multidisciplinary
Bin Xu, Yongsheng Han, Lei Zhao, Yi Min Xie
Summary: This article proposes a design method to minimize compliance or maximize fundamental natural frequency of continuum structures in additive manufacturing processes. Topology optimization is performed using the BESO method, with sensitivity expressions derived for the objectives. Various thin feature and support structure constraints are investigated, showing the effectiveness of the proposed method in achieving optimized solutions for continuum structures that are additive manufacturing friendly.
ENGINEERING OPTIMIZATION
(2021)
Article
Mechanics
Ali Radhi, Vincent Iacobellis, Kamran Behdinan
Summary: Additive Manufacturing (AM) is a disruptive production and prototyping technology, and topology optimization can generate complex structure designs suitable for AM. However, AM has its own limitations and stress factors, which, when not considered, require postprocessing and reduce the performance of optimized structures. Therefore, a stress-based optimization framework for AM is proposed to ensure designs meet the geometric constraints of AM.
MECHANICS BASED DESIGN OF STRUCTURES AND MACHINES
(2023)
Article
Computer Science, Interdisciplinary Applications
Florian Dugast, Albert C. To
Summary: This paper presents a topology optimization algorithm for elastoplastic and layer-by-layer simulation in additive manufacturing. The objective is to minimize stress or displacement in the build direction by modifying design variables in the support domain to prevent build failures or large deformations. The elastoplastic model follows an elastic predictor plastic corrector algorithm with the von Mises criterion and bilinear hardening. The topology optimization is density-based and the objective function gradient is obtained with the adjoint method.
STRUCTURAL AND MULTIDISCIPLINARY OPTIMIZATION
(2023)
Article
Engineering, Mechanical
C. Boursier Niutta, A. Tridello, G. Barletta, N. Gallo, A. Baroni, F. Berto, D. S. Paolino
Summary: This paper proposes a generalized formulation of defect-driven topology optimization (TO) for fatigue design, named TopFat. The proposed method limits the first principal stress in accordance with the defect size distribution of the additive manufacturing process. The results show that considering the defect population significantly affects the final topology and leads to feasible optimum solutions.
ENGINEERING FAILURE ANALYSIS
(2022)
Article
Mechanics
Miao Zhao, David Z. Zhang, Zhonghua Li, Tao Zhang, Hailun Zhou, Zhihao Ren
Summary: A novel parametric approach was proposed to improve the mechanical properties of lattice structures. The performance and deformation behavior of lattice structures with different taper struts were investigated through finite element analysis and experimental tests. The results show that tapered struts can reduce stress concentration and increase the elastic modulus of the structure.
COMPOSITE STRUCTURES
(2022)
Article
Computer Science, Interdisciplinary Applications
Ruiliang Feng, Xianda Li, Lin Zhu, Atul Thakur, Xiangzhi Wei
Summary: Extrusion-Based Additive Manufacturing is widely used, but the need for supports contributes to material waste. This study proposes a two-level support structure to save support materials, with optimized shapes and topologies, leading to significant material and time savings. Validation experiments on benchmark models confirmed the effectiveness of the developed approach.
ROBOTICS AND COMPUTER-INTEGRATED MANUFACTURING
(2021)
Article
Engineering, Manufacturing
Yunfeng Luo, Ole Sigmund, Quhao Li, Shutian Liu
Summary: This paper proposes a novel topology optimization procedure for structures designed for additive manufacturing, where enclosed voids are filled with porous materials for support and cannot be removed. The procedure automatically determines whether to eliminate enclosed voids or use infill to support them, effectively addressing a challenging problem in structure design. Experimental examples demonstrate the effectiveness of the procedure in optimizing layouts and enhancing performance.
ADDITIVE MANUFACTURING
(2022)
Article
Mechanics
Yingchun Bai, Jiayu Gao, Chengxiang Huang, Chao Jiang, Xu Han
Summary: Compared to standard structures with pure solid members, sandwich structures offer mechanical advantages in terms of strength-to-weight ratio, stiffness-to-weight ratio, energy absorption capabilities, and lightweight potential. This paper systematically investigates sandwich structures with pure-lattice/solid-lattice infill using additive manufacturing in combination with topology optimized design and validation. Equivalent material properties of infill BCC and F2BCC lattices are determined through finite element simulation. The newly developed sandwich structural topology optimization algorithm based on two-step density filtering is employed to obtain conceptual designs with pure or hybrid infill. The topology optimized structures are fabricated using additive manufacturing and validated through three-point bending experiments and numerical simulations.
COMPOSITE STRUCTURES
(2023)
Article
Computer Science, Interdisciplinary Applications
Jianchao Chen, Jiaxun Cheng, Xinye Zhang, Jiachun Wang, Changdong Zhang
Summary: This paper proposes an effective method to eliminate supports in additive manufacturing during the topology optimization stage. Numerical examples and experiments are provided to validate the capabilities of the presented algorithm.
STRUCTURAL AND MULTIDISCIPLINARY OPTIMIZATION
(2022)
Article
Engineering, Civil
Haleh Sadat Kazemi, Seyed Mehdi Tavakkoli
Summary: In this paper, a density-based topology optimization method is proposed for generating support structures in additive manufacturing. Isogeometric analysis is used to model the geometry and structural analysis of the main and support structures. Two cases are investigated for modeling the problem, one where the design domain of supports is easily separated from the main structure, and another where the supports are designed in the voids of the optimized main structure. A parameterization technique is proposed to identify the design domain of supports in the second case. The results show that the proposed method effectively creates supports to protect the overhanging surfaces of the main structure.
STRUCTURAL ENGINEERING AND MECHANICS
(2023)
Article
Chemistry, Multidisciplinary
Fernando Senhora, Emily D. Sanders, Glaucio H. Paulino
Summary: Spinodal architected materials optimize design of multiscale structures by varying spinodal class, orientation, and porosity, leading to efficient material placement along stress trajectories with enhanced mechanical and biological functions.
ADVANCED MATERIALS
(2022)
Article
Engineering, Manufacturing
Zhiping Wang, Yicha Zhang, Shujie Tan, Liping Ding, Alain Bernard
Summary: Support structures are crucial for additive manufacturing processes, with the number and position of support points directly impacting the performance and final printing quality. This paper proposes a method to determine support points, optimizing their distribution while ensuring manufacturability, particularly useful for complex structures in medical applications.
ADDITIVE MANUFACTURING
(2021)
Article
Engineering, Mechanical
Miao Zhao, Xinwei Li, David Z. Zhang, Wei Zhai
Summary: Compared to single-phase structures, interpenetrating lattice structures based on triply periodic minimal surfaces exhibit a wide range of adjustable physical and mechanical properties. The influence of volume fraction and interpenetrating parameter on the mechanical properties and deformation behavior of these structures are investigated using representative volume elements and periodic boundary conditions. The results show that the mechanical properties are highly dependent on the interpenetrating parameter, and different deformation mechanisms can be achieved by adjusting this parameter. The experimentally validated 3D-printed samples confirm the effectiveness of the proposed optimization framework, which simultaneously optimizes the distribution of volume fraction and interpenetrating parameter, for lightweight applications.
INTERNATIONAL JOURNAL OF MECHANICAL SCIENCES
(2023)
Article
Chemistry, Multidisciplinary
Nicolas Alberto Sbrugnera Sotomayor, Fabrizia Caiazzo, Vittorio Alfieri
Summary: Additive manufacturing has revolutionized the production of complex lightweight designs in the past few decades, leading to a new era in the design process. It is crucial to consider multiple stages in the design for additive manufacturing (DfAM) process and implement guided-design frameworks to efficiently manage the process. This paper aims to minimize the number of design evaluations through optimization, design, and simulation tools, while focusing on implementing design optimization strategies to maximize additive manufacturing capabilities.
APPLIED SCIENCES-BASEL
(2021)
