Topology Optimization for Fused Deposition Modeling Process

Additive manufacturing (AM) processes enable the production of functional parts with complex geometries, multi-materials as well as individualized mass production. Another significant benefit of AM is the ability to produce optimized geometries with near- perfect strength-to-weight ratios. Weight plays a crucial role in many functional parts such as parts used in vehicle and aircraft industries. Current topology optimization techniques, a powerful tool for weight reduction, do not work well for such kind of process since AM methods necessitate applying own dedicated design rules. This paper investigates the issues and opportunities for the application of topology optimization methods for (AM). Converting topology optimization output files to usable AM input data for production of meso-scale structures for realizing intermediated density regions are investigated. This methodology is then implemented for the fused deposition modeling process (FDM). Based on the implemented tool a case study is redesigned, fabricated and evaluated.