<p>Additive manufacturing is a revolutionary technique that provides significant design freedom, enabling the production of complex geometries. It has simplified the production of intricate structures, specifically those resulting from topology optimization. However, most topologically optimized components require support structures to prevent collapse or wrapping of overhanging areas, which increases material use, printing time, and post-processing effort. In this research, an enhanced topology optimization method is proposed to design self-supporting structures with an overhang constraint integrated into the solid isotropic material with penalization (SIMP) method. The methodology involves a sequential correction-re-optimization strategy. First, overhang detection is performed using a local discrete method based on a density threshold. Second, for each detected area, two inclined correction paths oriented at <InlineEquation ID="IEq1"> <EquationSource Format="TEX">\(\:\pm\:{45}^{^\circ\:}\)</EquationSource> </InlineEquation>are generated, and all intersected finite elements are assigned a fixed solid-density during the re-optimization step. The process repeats until no unsupported regions remain. The proposed method is evaluated on two 2D benchmark problems: the Messerschmitt-Bolkow-Blohm (MBB) beam and the cantilever beam. For the 30% volume MBB case, the self-supporting topology shows a compliance increase of 5.7%, while printing time and material consumption are reduced by 26.6% and 60.6%, respectively. For the 40% volume cantilever beam, compliance increases by 4.8%, with a reduction by 35.2% in printing time and by 42.1% in mass. Computational time increases by 47.8% for the MBB beam but decreases by 53,3% for the cantilever beam. These results confirm that iteratively integrating the self-supporting constraint can produce printable, support-free optimized structures with minimal performance degradation.</p>

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An enhanced topology optimization method for the additive manufacturing of self-supporting structures

  • Intissar Antar,
  • Bassam Al Nahari,
  • Khalid Zarbane,
  • Mohamed El Oumami

摘要

Additive manufacturing is a revolutionary technique that provides significant design freedom, enabling the production of complex geometries. It has simplified the production of intricate structures, specifically those resulting from topology optimization. However, most topologically optimized components require support structures to prevent collapse or wrapping of overhanging areas, which increases material use, printing time, and post-processing effort. In this research, an enhanced topology optimization method is proposed to design self-supporting structures with an overhang constraint integrated into the solid isotropic material with penalization (SIMP) method. The methodology involves a sequential correction-re-optimization strategy. First, overhang detection is performed using a local discrete method based on a density threshold. Second, for each detected area, two inclined correction paths oriented at \(\:\pm\:{45}^{^\circ\:}\) are generated, and all intersected finite elements are assigned a fixed solid-density during the re-optimization step. The process repeats until no unsupported regions remain. The proposed method is evaluated on two 2D benchmark problems: the Messerschmitt-Bolkow-Blohm (MBB) beam and the cantilever beam. For the 30% volume MBB case, the self-supporting topology shows a compliance increase of 5.7%, while printing time and material consumption are reduced by 26.6% and 60.6%, respectively. For the 40% volume cantilever beam, compliance increases by 4.8%, with a reduction by 35.2% in printing time and by 42.1% in mass. Computational time increases by 47.8% for the MBB beam but decreases by 53,3% for the cantilever beam. These results confirm that iteratively integrating the self-supporting constraint can produce printable, support-free optimized structures with minimal performance degradation.