Integration of FDM process-structure relationship in topology optimization formulation

Additive manufacturing technologies, such as fused deposition modeling, enable the production of intricate designs, overcoming the limitations of traditional methods. These complex designs often result from topology optimization, a powerful approach for creating lightweight and high-performing structures. To fully leverage the design and manufacturing freedom offered by additive manufacturing and topology optimization, it is essential to consider the influence of additive manufacturing process parameters on the mechanical properties of printed components. This paper presents a new approach that integrates Fused Deposition Modeling Process-Structure–Property relationships and raster direction into the topology optimization formulation, while accounting for anisotropic material characteristics. These relationships are formulated as a regression model established through a Taguchi design of experiments and experimental tensile tests on printed specimens. The effectiveness of the proposed approach is validated by comparing its results to those of the classical optimization method applied to benchmark cases, as well as through mechanical stiffness tests of the optimized printed parts.