Topological optimization with support structure filter for additive manufacturing

Resumo

Topological optimization proves to be an important tool for analysis and design of projects, seeking the best structural performance within criteria such as stiffness, strength, economy, and stability. However, manufacturing optimized structures by traditional methods is not always feasible, due to the complex and unconventional configuration of the geometry. Additive Manufacturing (AM) emerges as a solution, allowing the production of objects layer by layer, without the need for molds. However, angles greater than 45° formed in the geometry may require support material to avoid failures and deformations during printing, increasing material costs and manufacturing time. This study combines topological optimization with AMfilter, a support structure filter for AM developed by Langelaar (2016). Using the open-source MATLAB® code of 88 lines developed by Andreassen et al. (2010), in which AMfilter is integrated during the numerical analysis of the topological optimization problem. The objective is to evaluate the effectiveness of topological optimization with the implementation of AMfilter, through simulations of printing the optimized models, highlighting the potential cost reduction benefits. The results demonstrate a decrease in the use of supports, and in some cases, their complete elimination, making this methodology efficient in the cases examined in this study.