Stress-constrained topology optimization for material extrusion polymer additive manufacturing

Abstract This paper presents a comprehensive numerical and experimental study on stress-constrained topology optimization for Fused Deposition Modeling (FDM) additive manufacturing. The qp method is employed to avoid the singularity issue of problems. P-norm function with stability transformation adopted build global stress constraint iterative corrections eliminate gap between maximum local stress. Heaviside projection generate clear-cut 0–1 designs. Two benchmark examples have been studied algorithm. Experiments are performed topologically optimized MBB beam investigate impact FDM process parameters, including deposition path direction, building slicing layer height, resulted structural strength. designs without comparatively tested experiments. stress-minimization subject different parameters compared both numerically experimentally. show that direction evidently affect derived Moreover, overthin members may severely degrade strength due manufacturing loading uncertainties.