Optimization of parts manufactured using continuous fiber three-dimensional printing technology

In this paper, a topology optimization framework for continuous composite fiber three-dimensional (3D) printing is presented. The problem of compliance minimization with respect to the design parameters of density and orientation is formulated and solved numerically using the proposed filtration procedure, ensuring a smooth fiber orientation change and fast convergence. The optimization algorithm is based on the gradient method and implemented using Abaqus finite-element analysis software. It allows optimization of parts within complex computer-aided design models and considers different types of nonlinearities in the finite-element model. The efficiency of the proposed method is evaluated on examples of two-dimensional (2D) and 3D cantilevers, which reveals the general similarity of the resulting shapes in 2D and 3D. Nevertheless, spatially oriented trusses are clearly defined in the result part of the 3D problem. The pedal support of a race car is optimized using the developed framework with an optimization domain based on the geometry of the conventional metallic structure. The resulting topology and fiber orientation are postprocessed using special software for printing trajectory generation and produced by a continuous composite fiber 3D printer.