Design Optimization of Additively Manufactured Components Using Simulation-Based Analysis of Infill Structures

Abstract

Abstract Additive manufacturing (AM) has revolutionized the manufacturing industry, allowing the production of complex, lightweight components with specific properties. This has created opportunities for customized parts with optimized performance and cost-efficiency compared to traditional manufacturing. Infill structures are used to fill the voids inside the component during layer-by-layer manufacturing. These structures, such as grids and honeycombs, optimize mechanical properties, reduce weight, and save production time. However, investigating the mechanical properties of components with different infill structures is typically done experimentally, which is time-consuming and expensive. This paper proposes a simulation-based approach to investigate the influence of infill structure parameters on the mechanical properties of components made from AISI 316L stainless steel. Two-dimensional grid and honeycomb infill structures are studied, considering infill degree, cell wall thickness and spatial orientation relative to the load direction. The study employs a parametric design approach to generate different infill structures for simulation and validation. This paper provides a simulation-based methodology for varying and evaluating design parameters for AM processes using grid and honeycomb infill structures. The findings can be used to optimize lightweight component design for specific applications, improving performance and cost-efficiency. The study contributes to the field of Design for Additive Manufacturing (DfAM).