Topology Optimization for Multi-Axis Additive Manufacturing Considering Overhang and Anisotropy

TL;DR

This paper introduces a space-time topology optimization framework for multi-axis additive manufacturing that considers overhang constraints, collision avoidance, and material anisotropy, leading to manufacturable and optimal complex designs.

Contribution

It presents a novel optimization approach that integrates build orientation, overhang limits, collision mitigation, and anisotropic material behavior in multi-axis AM.

Findings

Optimized designs respect overhang and collision constraints.

Incorporating anisotropy improves structural performance.

Numerical examples validate the framework's effectiveness.

Abstract

Topology optimization produces designs with intricate geometries and complex topologies that require advanced manufacturing techniques such as additive manufacturing (AM). However, insufficient consideration of manufacturability during the optimization process often results in design modifications that compromise the optimality of the design. While multi-axis AM enhances manufacturability by enabling flexible material deposition in multiple orientations, challenges remain in addressing overhang structures, potential collisions, and material anisotropy caused by varying build orientations. To overcome these limitations, this study proposes a novel space-time topology optimization framework for multi-axis AM. The framework employs a pseudo-time field as a design variable to represent the fabrication sequence, simultaneously optimizing the density distribution and build orientations. This approach ensures that the overhang angles remain within manufacturable limits while also mitigating collisions. Moreover, by incorporating material anisotropy induced by diverse build orientations into the design process, the framework can take the scan path-dependent structural behaviors into account during the design optimization. Numerical examples demonstrate that the proposed framework effectively derives feasible and optimal designs that account for the manufacturing characteristics of multi-axis AM.