The Impact of Additive Manufacturing Constraints and Design Objectives on Structural Topology Optimization

To analyze the impact of different objective functions and additive manufacturing (AM) constraints on structural topology optimization, it is necessary to perform an in-depth comparative study. This analysis should consider specific structural design factors, such as compliance, volume, or stress minimization, and assess their effects on the topology optimization for AM. In addition, the inclusion of AM constraints can have a significant influence on various aspects, including optimal part geometry, part volume, support structure volume, and structural performance. Thus, it is essential to investigate and compare these factors to determine the optimal part design for AM. This study focuses on comparing topology optimization results obtained using compliance, stress, or multi-objective minimization, with and without AM constraints. A comparative analysis was conducted in the study, utilizing three structural design examples: cantilever beam, bridge-shaped structure, and L-shaped beam. The comparison results provide insights into the effects of build orientation, AM constraints such as overhang, and different design objectives on the structural topology optimization for AM.