A Topology Optimization Algorithm Based on the Overhang Sensitivity Analysis for Additive Manufacturing

Abstract

The integration of topology optimization(TO) and additive manufacturing(AM) has the huge potential to expand the design freedom of parts. However, traditional topology optimization approaches are not tailored to the particular characteristics of AM processes, resulting in a large number of overhangs in these designs, which lead to use of sacrificial support structures and increase the manufacturing cost. This paper presents an AM-restrained topology optimization approach based on the overhang sensitivity analysis. The overhangs can be explicitly expressed by the design variable and considered to be a minimization goal of the optimization process, in which the overhang sensitivity is combined with other performance sensitivities to update design variables. The effectivity and robustness of the proposed method is demonstrated by the typical cantilever beam and the MBB beam, then validated through the fused deposition modelling(FDM) 3D printing.