TOPOLOGY OPTIMIZATION FOR ADDITIVE MANUFACTURING
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Date
2021-05
Authors
Kassym, Kazybek
Journal Title
Journal ISSN
Volume Title
Publisher
Nazarbayev University School of Engineering and Digital Sciences
Abstract
The main aim of this project is to assess the use of topology optimization (TO) methods in
additive manufacturing in conjunction with the effect of 3D-printing parameters on the resulting
strength of the printed objects. The two most common topology optimization methods, i.e., Density
and Level-Set, were used with the aim of minimizing the mass of a given prototype solid entity
while maintaining, to the extent possible, its tensile strength. A family of designs was produced
for different levels of retained mass. Specifically, topologically optimized designs were generated
for mass levels ranging from 100% to 50% of the original entity’s mass with a 10% reduction step.
These designs were experimentally assessed in conjunction with varying infill patterns and infill
density 3D-printing parameters. The assessment was carried out systematically via tensile testing
of 126 specimens and generation of the corresponding stress-strain graphs. In summary, the non-
optimized entities and the 10%-mass-reduced designs produced practically identical results,
whereas the 30% and 50%-mass-reduced ones exhibit slightly lower values for the max load at the
break. Furthermore, the employed Density method seems to produce results that are better suited
for 3D printing as it was computationally inexpensive, and it consistently generated designs that
outperformed the ones generated by the employed Level-Set method. Regarding 3D-printing
parameters, we can state that the ‘triangle’, ‘line’ and ‘grid’ patterns produce equal quality
printouts. Finally, the lower value of infill density produced unexpected results and break points
that could be possibly explained by the introduction of large gaps in the interior of the printed
model. Further studies are needed to assess, qualitatively and quantitatively, the effect of infill
density on the strength of printed objects.
Description
Keywords
3D, Research Subject Categories::TECHNOLOGY, 3D printer, topology optimization, TO, Type of access: Gated Access
Citation
Kassym, K. (2021). Topology Optimization for Additive Manufacturing (Unpublished master's thesis). Nazarbayev University, Nur-Sultan, Kazakhstan