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In this paper, a Laser Powder Bed Fusion (LPBF) process is studied comparing the design of a Diesel piston with and without topological optimization. Starting from a commercial piston, an equivalent model and a topologically optimized one are designed, additively manufactured and post processed to set-up the starting framework to evaluate how Additive Manufacturing (AM) may impact the sustainability of an automotive product. Results highlighted a 27% mass reduction with a reduction of AM process duration of about 41% passing from a process lasted about 49 h for an AM piston with the original shape to about 29 h for 3D printing the topologically optimized one. Limits and further investigation are then discussed also in the perspective of a future assessment via LCA.

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Preliminary Comparison of the Additive Manufacturing Sustainability in Case of Topologically Optimized Components Through a Piston Case Study

  • 会议论文

  • 发表日期：

    2025年

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  • Hemanth Kollipara,
  • Luca Belluomo,
  • Daniele Cortis,
  • Michele Bici,
  • Donato Orlandi,
  • Francesca Campana

摘要

In this paper, a Laser Powder Bed Fusion (LPBF) process is studied comparing the design of a Diesel piston with and without topological optimization. Starting from a commercial piston, an equivalent model and a topologically optimized one are designed, additively manufactured and post processed to set-up the starting framework to evaluate how Additive Manufacturing (AM) may impact the sustainability of an automotive product. Results highlighted a 27% mass reduction with a reduction of AM process duration of about 41% passing from a process lasted about 49 h for an AM piston with the original shape to about 29 h for 3D printing the topologically optimized one. Limits and further investigation are then discussed also in the perspective of a future assessment via LCA.