Abstract
Topology Optimisation (TO) is one of the most popular design tools for additive manufacturing (AM) technologies. Indeed, AM allows creating the complex geometries provided by TO algorithms. However, AM processes such as Selective Laser Melting (SLM) or Electron Beam Melting (EBM) suffer from local slight fluctuations of the process parameters during the building phase, leading to the formation of defects, like pores, clusters of pores, lack of fusion defects, that drive the fatigue response of the material. For this reason, the TO algorithm must consider the presence of the defect population to reliably design the optimised component in the fatigue regime. Recently, the Authors developed a defect-driven TO algorithm with proprietary code, named TopFat, that exploits the Murakami fatigue model to safely design the AM optimised components. In the present paper, the TopFat methodology is extended to the HyperWorks commercial software to unlock a wide-ranging set of industrial and academic applications. This extension allows including the defect population within the TO algorithm without the need for a specific complex code.
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