Design and Development of an Additive Manufactured Component by Topology Optimisation

This paper investigates a design and development process for Electron Beam Melting (EBM) which incorporates a simulation-driven design process called topology optimisation. Research consists of a review of EBM design principles and validation of mechanical properties for Ti-6Al-4V ELI. Findings are applied to a case study whereby a pair of suspension uprights are redesigned and manufactured by EBM with the objective of mass reduction. Previous studies indicate that optimisation shape controls can potentially minimise the number of supports required for EBM. Meanwhile, a parametric solid/surface modelling approach can allow for greater control of design intent when designing for larger assemblies or structures. Application of the proposed strategy resulted in the case study having a 36 % reduction in mass in comparison to a CNC aluminium design. Whilst the EBM alternative design also yields an 86% reduction in raw material use, there is a sevenfold increase in cost for manufacture alone. This work is an example of topology optimisation being a suitable approach when Designing for AM (DfAM). But, the cost and time constraints associated with EBM limits application of the process to high-performance industries such as motorsport, aerospace, or tooling solutions.