Integration of reverse engineering and topology optimization with additive manufacturing

Abstract

Additive manufacturing (AM) is highly recommended for producing complex parts which mostly comes from the flexibility of integration with design aspects. Currently, design optimization techniques such as topology optimization (TO) is becoming common for the reduction of mass of the parts. However, there are some issues that are not well elaborated particularly the constraints coming to TO from the design of the parts and constraints coming from AM production. The case study presented in the paper represents a mechanical component with simple geometry, where reverse engineering (RE) and TO have been applied for CAD model creation and redesign, and production of the part using laser powder bed fusion AM process. The aim of the work has been to integrate RE, TO, and AM when the part with simple geometry becomes complex after redesigning in terms of shape, fabrication, and accuracy, taking into consideration the constraints to the TO coming from design and AM. Further investigation of the constraints from the design of the part and AM to the TO are required for the improvement of the whole process.