Controlling local overheating in topology optimization for additive manufacturing

Abstract A novel constraint to prevent local overheating is presented for use in topology optimization (TO). The very basis the Additive Manufacturing (AM) process physics. AM enables fabrication of highly complex topologically optimized designs. However, a major concern especially metal processes leading part failure, poor surface finish, lack dimensional precision, and inferior mechanical properties. It should therefore be taken into account at design stage. including detailed simulation would make intractable. Hence, computationally inexpensive thermal model, recently literature, used detect zones prone given geometry. model integrated density-based TO combination with robust formulation, applied various numerical test examples. found that existing AM-oriented methods which rely purely on overhang control do not ensure avoidance. Instead, proposed physics-based able suppress geometric features causing delivers results efficient manner.