2019, Auricchio, Ferdinando, Bonetti, Elena, Carraturo, Massimo, Hömberg, Dietmar, Reali, Alessandro, Rocca, Elisabetta

In this paper a phase-field approach for structural topology optimization for a 3D-printing process which includes stress constraint and potentially multiple materials or multiscales is analyzed. First order necessary optimality conditions are rigorously derived and a numerical algorithm which implements the method is presented. A sensitivity study with respect to some parameters is conducted for a two-dimensional cantilever beam problem. Finally, a possible workflow to obtain a 3D-printed object from the numerical solutions is described and the final structure is printed using a fused deposition modeling (FDM) 3D printer.

2019, Ebeling-Rump, Moritz, Hömberg, Dietmar, Lasarzik, Robert, Petzold, Thomas

In Topology Optimization the goal is to find the ideal material distribution in a domain subject to external forces. The structure is optimal if it has the highest possible stiffness. A volume constraint ensures filigree structures, which are regulated via a Ginzburg-Landau term. During 3D Printing overhangs lead to instabilities, which have only been tackled unsatisfactorily. The novel idea is to incorporate an Additive Manufacturing Constraint into the phase field method. A rigorous analysis proves the existence of a solution and leads to first order necessary optimality conditions. With an Allen-Cahn interface propagation the optimization problem is solved iteratively. At a low computational cost the Additive Manufacturing Constraint brings about support structures, which can be fine tuned according to engineering demands. Stability during 3D Printing is assured, which solves a common Additive Manufacturing problem.