Parametric studies and manufacturability experiments on smooth self-supporting topologies

Yun-Fei Fu, Bernard Rolfe, Louis N.S. Chiu, Yanan Wang, Xiaodong Huang, Kazem Ghabraie

Research output: Contribution to journalArticleResearchpeer-review

10 Citations (Scopus)

Abstract

This paper aims to explore the effects of optimisation parameters (the filter radius, mesh size, and target volume fraction) on the compliance and manufacturability of smooth self-supporting topologies for additive manufacturing (AM); and conduct manufacturability experiments of selected simulation results with the Selective Laser Melting (SLM) technology. In this study, smooth self-supporting topologies are obtained with a combined method of the Solid Isotropic Microstructure with Penalization method (SIMP) with the smooth boundary representation and Langelaar's AM filter. Numerical examples illustrate that a higher filter radius can lead to simpler smooth self-supporting topologies, but curved top corners that violate the critical overhang angle of 45° are inevitably generated. Additionally, the mesh size is found to be not as an important factor as the filter radius in affecting the manufacturability and performance. As a result of the self-supporting constraint, a small volume fraction can easily result in structural discontinuity. The experimental results demonstrate that the self-supporting topologies obtained are all printable in SLM.

Original languageEnglish
Pages (from-to)22-34
Number of pages13
JournalVirtual and Physical Prototyping
Volume15
Issue number1
DOIs
Publication statusPublished - 2020

Keywords

  • Additive manufacturing
  • elemental volume fractions
  • selective laser melting (SLM)
  • smooth self-supporting design
  • solid isotropic microstructure with penalisation method (SIMP)

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