Manufacturing Constraints in Topology Optimization for the Direct Manufacturing of Extrusion-Based Additively Manufactured Parts

Abstract

Additive manufacturing is a potentially disruptive technology with a high impact on supply chains and part design. While generally allowing much higher degrees of freedom in design than formative and subtractive manufacturing techniques, the necessity of support structures can diminish the impact of additive manufacturing. This article presents a methodology based on finite spheres to integrate knowledge about process limitations into topology optimization for the direct extrusion-based additive manufacturing of parts with maximized stiffness and strength and minimized support structures. This methodology has been included within our self-developed Freeware Z88 Arion® V3. We investigated the impact of the manufacturing constraints on the additive manufacturing process regarding effective material usage on application test examples. The test results showed that the design proposals created while applying the finite spheres and two-step smoothing needed significantly less or no support material for all application examples.