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<p>Anisotropy during the material extrusion process significantly influences the structural characteristics of additive manufacturing (AM) components. This study addresses carbon fiber-reinforced composites’ anisotropic properties and manufacturability constraints by proposing a design framework that integrates topology optimization with post-processing. Based on the solid isotropic material with penalization (SIMP) method, a two-stage optimization strategy, comprising coarse-grid angular pre-optimization followed by local fine-scale co-optimization, is developed to minimize structural compliance. Additionally, a non-uniform rational B-spline (NURBS) surface fitting technique is employed to smooth jagged mesh boundaries, thereby enhancing geometric accuracy. To improve manufacturability, a spectral clustering algorithm divides the fiber orientation distribution into distinct manufacturing regions, forming an executable path planning scheme. Case studies demonstrate that the proposed method reduces simulated structural compliance by 39.2% to 51.5% compared to single-angle strategies, significantly outperforming the traditional approach. Experimental results confirm a 29.5% to 36.9% stiffness enhancement in printed components, effectively addressing the mismatch between optimized design and manufacturing performance. This study offers a systematic solution that balances mechanical properties with process feasibility for topology optimization of anisotropic materials in AM.</p>

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A topology optimization and post-processing method for additive manufacturing considering anisotropy and manufacturability

  • 期刊论文

  • 发表日期：

    2026年5月18日

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  • Runrui Liu,
  • Xiaoyu Wang,
  • Zhen Peng,
  • Ziyi Wang,
  • Yonglei Su,
  • Jian Wang,
  • Yunlong Tang,
  • Wei-Hsin Liao,
  • Qiang Gao

摘要

Anisotropy during the material extrusion process significantly influences the structural characteristics of additive manufacturing (AM) components. This study addresses carbon fiber-reinforced composites’ anisotropic properties and manufacturability constraints by proposing a design framework that integrates topology optimization with post-processing. Based on the solid isotropic material with penalization (SIMP) method, a two-stage optimization strategy, comprising coarse-grid angular pre-optimization followed by local fine-scale co-optimization, is developed to minimize structural compliance. Additionally, a non-uniform rational B-spline (NURBS) surface fitting technique is employed to smooth jagged mesh boundaries, thereby enhancing geometric accuracy. To improve manufacturability, a spectral clustering algorithm divides the fiber orientation distribution into distinct manufacturing regions, forming an executable path planning scheme. Case studies demonstrate that the proposed method reduces simulated structural compliance by 39.2% to 51.5% compared to single-angle strategies, significantly outperforming the traditional approach. Experimental results confirm a 29.5% to 36.9% stiffness enhancement in printed components, effectively addressing the mismatch between optimized design and manufacturing performance. This study offers a systematic solution that balances mechanical properties with process feasibility for topology optimization of anisotropic materials in AM.