Development and Validation of Optimized Multiscale Structures in 3D-Printed Polymers: An Integrated Simulation and Experimental Approach

Resumo

This study proposes an integrated workflow that combines topology optimization, numerical simulation, and additive manufacturing for the development and validation of polymer structures subjected to bending. The methodology employs the SIMP method to redistribute material within structural models, with the results converted into lattice geometries using a Diamond-type unit cell. Finite Element Analysis is used to simulate the mechanical behavior of the optimized geometries, while fabrication is carried out through Fused Deposition Modeling using PLA filament. The specimens are then experimentally evaluated through three-point bending tests, allowing for validation of the computational model. The results show that the optimized structure exhibits higher specific stiffness and mechanical behavior influenced by the geometric characteristics of the lattice. The good correlation between simulated and experimental data in the elastic region validates the adopted approach, while the discrepancies observed in the post-yield phase reflect the effects of printing-induced anisotropy, geometric imperfections, and simplified constitutive modeling. This work highlights the potential of topology optimization combined with additive manufacturing as an effective strategy for designing lightweight components, while also emphasizing the challenges related to accurately predicting the mechanical behavior of complex structures.