Towards CAD-Based Mathematical Optimization for Additive Manufacturing – Designing Forming Tools for Tool-Bound Bending

Abstract The trend towards flexible, agile, and resource-efficient production systems requires a continuous development of processes as well tools in the area forming technology. To create load-adjusted weight-optimized tool structures, we present an overview new algorithm-driven design optimization workflow based on mixed-integer linear programming. Loads boundary conditions for mathematical are taken from numerical simulations. They transformed into time-independent point loads generating physical uncertainty parameters model. CAD-based is used topology geometry generation truss-like structure. Finite element simulations performed to validate structural strength optimize shape lattice nodes reduce mechanical stress peaks. Our takes full advantage geometrical freedom additive manufacturing by considering geometry-based constraints. Depending process, use lower upper bounds diameter members truss associated yield strengths. An additively manufactured flexible blank holder demonstrates optimization.