Topology Optimization by the use of 3D Printing Technology in the Product Design Process

Abstract

The design process of a new product includes various stages, one of which is the evaluation of an idea for prototype manufacturing. The use of additive manufacturing is the most efficient and effective method for producing prototypes. In order to maximize the benefits from the use of additive manufacturing, we should choose the suitable printing parameters. The inner wall thickness is a vital parameter for defining the quantity of raw material used and the model solidity. Depending on the selected technique of additive manufacturing, the thickness of the inner wall may differ. In this study, we initially print furniture models with different wall thicknesses using the Inject Binder technique, and then we check their durability and resilience through compression tests. Evaluating the study results indicates the hollow printed specimens have high durability during compression tests and can be used to evaluate a design idea. Using the facts derived from lab tests, we perform Topology Optimization studies under different circumstances to evaluate the method and come up with the optimal design solution. Initially, the Topology Optimization study concerned only the table surface and not the whole model. The following studies were performed for the whole model, with different constraints and load cases defined. Then, the optimized models are redesigned in order to improve their durability. The performed studies show that Topology Optimization is a powerful tool, which is able to support the designers/ engineers to take the right decision during the design process.