Topology Optimization for additive manufacturing with distortion constraints

An important cause of failure in powder bed additive manufacturing is the distortion part due to thermal shrinkage during printing and relaxation residual stresses after its release from base plate. In this paper, Additive Manufacturing simulations are coupled with Topology Optimization order generate designs that not susceptible associated distortion. Two possible causes accounted for: recoater collision global product. Both considered by simulation build process defined as constraints context a Solid Isotropic Material Penalization method based topological optimization. The adjoint used derive sensitivities constraints. demonstrated 2D 3D optimization bracket. Next changes, obtained show features aimed at facilitating process. These resemble supports routinely applied manufacturing. formulated were found prevent excessive failures all cases, against modest increase compliance • on distortions printing. Distortion separation plate considered. FEM utilized material modeled inherent strains technique. Adjoint calculate design variables. optimized often feature auxiliary support structures.