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A post-topology optimization process for overhang elimination in additive manufacturing: design workflow and experimental investigation

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Abstract

Although structural design complexities do not potentially pose challenges to many additive manufacturing technologies, several manufacturing constraints should be considered in the design process. One critical constraint is a structure's unsupported or overhanging features. If these features are not reduced or eliminated, they can cause a decline in part surface quality, inhibit print success, or increase production time and cost due to support printing and removal. To eliminate these features, a new post-topology optimization strategy is proposed. The design problem is first topologically optimized, then boundary identification and overhang detection are carried out. Next, additional support-free struts subject to a specified thickness and angle are introduced to support previously detected infeasible features. This addition can increase the structure’s volume; therefore, an optional volume correction stage is introduced to obtain a new but lower volume fraction which will be used in the final topology optimization, boundary identification, and overhang elimination stages. Experimental and numerical load–displacement relationships are established for varying overhang angle thresholds and minimum feature sizes.

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Acknowledgements

The authors would like to acknowledge the funding support received from the Natural Sciences and Engineering Research Council of Canada (NSERC), the Federal Economic Development Agency for Southern Ontario (FedDev Ontario), Siemens Canada Limited, and Petroleum Technology Development Fund (PTDF).

Funding

The authors appreciate all funding bodies. The authors also appreciate Jerry Ratthapakdee and Francis Dibia for their roles in printing and photo-capturing some of the sample structures presented in this work.

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Authors and Affiliations

  1. Multifunctional Design and Additive Manufacturing Lab, Department of Mechanical Engineering, University of Alberta, 9211 116 Street NW, Edmonton, AB, T6G 1H9, Canada

    Osezua Ibhadode

  2. Multi-Scale Additive Manufacturing Lab, University of Waterloo, 200 University Avenue West, Waterloo, ON, N2L 3G1, Canada

    Osezua Ibhadode, Zhidong Zhang & Ehsan Toyserkani

  3. Siemens Canada Limited, 9505 Côte-de-Liesse, Montréal, Québec, H9P 1A5, Canada

    Ali Bonakdar

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Osezua Ibhadode conceived and designed the study. Material preparation, data collection and analysis were performed by Osezua Ibhadode. The first draft of the manuscript was written by Osezua Ibhadode and reviewed by Zhidong Zhang. Ali Bonakdar and Ehsan Toyserkani supervised, reviewed, and funded the project. All authors read and approved the final manuscript.

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Ibhadode, O., Zhang, Z., Bonakdar, A. et al. A post-topology optimization process for overhang elimination in additive manufacturing: design workflow and experimental investigation. Int J Adv Manuf Technol 129, 221–238 (2023). https://doi.org/10.1007/s00170-023-12282-4

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