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This work presents a comprehensive study on the upgrading of the Upright body of a Formula Student racing car leveraging Topology Optimization (TO) and Selective Laser Melting (SLM). The part’s performance is judged by its mass, Camber Loss, and Toe Loss, originally 369 gr, 0.0193 °/g and 0.0235 °/g respectively. TO considered 6 different functional loading scenarios e.g. turning, bumps etc. The optimum design resulted in a mass of 259 gr, Camber Loss of 0.024 °/g and Toe Loss of 0.0176 °/g. The design was validated by Finite Element Analysis (FEA) and, then, different part orientations, layer thickness and support patterns were tried on commercially available SLM simulation software. Displacements of up to 1.135 mm were predicted for laser power of 500 W and scanning speed of 1200 mm/sec. For the best conditions determined on the simulator, the part was 3D printed on a SLM machine using AlSi10Mg powder, at an accuracy of the order of magnitude of 0.1 mm.

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Towards a Roadmap from Topological Optimization to Laser Powder Bed Fusion for Structural Machine Parts

  • 会议论文

  • 发表日期：

    2026年

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  • Pavlos Vasiloglou,
  • George-Christopher Vosniakos,
  • Marek Chodnicki

摘要

This work presents a comprehensive study on the upgrading of the Upright body of a Formula Student racing car leveraging Topology Optimization (TO) and Selective Laser Melting (SLM). The part’s performance is judged by its mass, Camber Loss, and Toe Loss, originally 369 gr, 0.0193 °/g and 0.0235 °/g respectively. TO considered 6 different functional loading scenarios e.g. turning, bumps etc. The optimum design resulted in a mass of 259 gr, Camber Loss of 0.024 °/g and Toe Loss of 0.0176 °/g. The design was validated by Finite Element Analysis (FEA) and, then, different part orientations, layer thickness and support patterns were tried on commercially available SLM simulation software. Displacements of up to 1.135 mm were predicted for laser power of 500 W and scanning speed of 1200 mm/sec. For the best conditions determined on the simulator, the part was 3D printed on a SLM machine using AlSi10Mg powder, at an accuracy of the order of magnitude of 0.1 mm.