Projection-based topology optimization algorithms for advanced manufacturing (INVITED)

Abstract eng:
The recent and rapid advancement of additive manufacturing technologies has provided engineers the capability to fabricate tailored structures with significant complexity at unprecedented length scales. In order to fully leverage these technologies, the associated new capabilities and limitations must be integrated into the design process. Herein, we extend projection-based topology optimization algorithms to address a number of advanced manufacturing methods including both polymer and metal additive manufacturing, and three-dimensional weaving. Fundamentally, all algorithms draw upon and extend the Heaviside Projection Method in order to impose manufacturing constraints, essentially utilizing tailored geometric and functional relationships between the independent design variables and the physical (and analysis) space. Specifically, we present new topology optimization algorithms for designing with multiple materials, considering support anchors for overhang regions, and respecting various geometric restrictions associated with 3D weaving. Through this, the end goal is to eliminate solution post-processing such that the optimized topologies are directly manufacturable.

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