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Topology optimization of easy-removal support structures for additive manufacturing

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Abstract

This paper presents a density-based topology optimization approach to design easy-removal support structures for additive manufacturing (AM). First, a multi-field structural parameterization is proposed for topology optimization by considering AM filtering technique that ensures the physical design being self-support. An easy-removal constraint is developed to generate porous structural patterns in the contact region between the support structures and its surroundings. An improved formulation is further proposed to prevent obtaining impractical solutions which contain one-node connection in the structural members. Besides, an overhang constraint and a design-dependent self-weight load are considered. As a result, the optimized support structures are self-support, able to support the overhang regions of the given prototype and possesses excellent mechanical properties to bear the self-weight of the entire AM part. It can be easily removed from both the prototype and the baseplate. Numerical examples and discussions are given to demonstrate its effectiveness and applicability.

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Notes

  1. For AM parts whose support structures can hardly be removed by post-processing, e.g., structural infill with closed walls, a self-support internal design is still preferable.

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Funding

This study was supported by the National Natural Science Foundation of China (Grant No. 51705311).

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Authors and Affiliations

  1. Shanghai Key Laboratory of Digital Manufacture for Thin-walled Structures, School of Mechanical Engineering, Shanghai Jiao Tong University, No. 800 Dong Chuan Rd., Shanghai, 200240, People’s Republic of China

    Mingdong Zhou, Yichang Liu & Chuang Wei

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  1. Mingdong Zhou
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  2. Yichang Liu
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  3. Chuang Wei
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Correspondence to Mingdong Zhou.

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Responsible Editor: Jianbin Du

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Zhou, M., Liu, Y. & Wei, C. Topology optimization of easy-removal support structures for additive manufacturing. Struct Multidisc Optim 61, 2423–2435 (2020). https://doi.org/10.1007/s00158-020-02607-2

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  • DOI: https://doi.org/10.1007/s00158-020-02607-2

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