Topology optimization for additive manufacturing

Abstract

Topology optimization provides design engineers the opportunity to create light and complex structural parts. Additive manufacturing produces parts easier than traditional manu-facturing. Due to the above mentioned flexibility, parts that are designed for AM have the same structural load as the old parts but with reduced mass. This study utilizes topology optimization techniques, aiming to reduce the mass of the existing parts. Further weight loss is achieved by implementing lattice structure. The core of this thesis is to examine the workflow to include topology optimization in the process of design for AM. This was achieved by minimizing the mass of two parts of an electric scooter, neck and platform. The study produced new geometry for the existing parts. Cost analysis showed that the optimized design was cheaper to manufacture using the same AM method than the initial one. Within the context of the present work we came across the pros and cons of topology optimization and FEA through the Inspire software and proved that load conditions may directly affect the final result and product.