Review on design and structural optimisation in additive manufacturing: Towards next-generation lightweight structures
János Plocher,Ajit Panesar +1 more
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TLDR
In this article, the state-of-the-art developments in the design for additive manufacturing (DfAM) and structural optimisation, becomes vital for successfully shaping the future AM-landscape.About:
This article is published in Materials & Design.The article was published on 2019-12-05 and is currently open access. It has received 330 citations till now. The article focuses on the topics: Generative Design & Topology optimization.read more
Citations
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Journal ArticleDOI
Material-structure-performance integrated laser-metal additive manufacturing.
TL;DR: In this article, a holistic concept of material-structure-performance integrated additive manufacturing (MSPI-AM) is proposed to cope with the extensive challenges of laser-based additive manufacturing.
Journal ArticleDOI
Architected cellular materials: A review on their mechanical properties towards fatigue-tolerant design and fabrication
Matteo Benedetti,A. du Plessis,A. du Plessis,Robert O. Ritchie,M. Dallago,Seyed Mohammad Javad Razavi,Filippo Berto +6 more
TL;DR: In this article, the authors discuss the progress to date in the improvement of the fatigue performance of cellular structures manufactured by additive manufacturing, especially metal-based, providing insights and a glimpse to the future for fatigue-tolerant additively manufactured architected cellular materials.
Journal ArticleDOI
A review of topology optimization for additive manufacturing: Status and challenges
TL;DR: It is shown that in the research of topology optimization for additive manufacturing, the integration of material, structure, process and performance is important to pursue high-performance, multi-functional and lightweight production.
Journal ArticleDOI
The effect of manufacturing defects on the fatigue life of selective laser melted Ti-6Al-4V structures
Yanan Hu,Shengchuan Wu,Shengchuan Wu,Philip J. Withers,J. Zhang,H.Y.X. Bao,Y.N. Fu,Guozheng Kang +7 more
TL;DR: In this paper, an eXtended defect zone (XDZ) describing the propensity for local plasticity during fatigue around a defect has been shown through numerical analysis to be a good indicator of the ranking of the threat to fatigue caused by differently located manufacturing defects.
Journal ArticleDOI
Wire and arc additive manufacturing : Opportunities and challenges to control the quality and accuracy of manufactured parts
TL;DR: In this paper, the authors focus on process planning including build orientation, slicing, and path planning, as well as the definition of process parameter selection from a single track to multi-track and multilayer, and finally geometric features from a thinwall to lattice structures with several case studies.
References
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Journal ArticleDOI
Lattice Structures and Functionally Graded Materials Applications in Additive Manufacturing of Orthopedic Implants: A Review
Dalia Mahmoud,Mohamed Elbestawi +1 more
TL;DR: In this article, the authors present a state-of-the-art overview of the use of additive manufacturing (AM) technologies to produce orthopedic implants from lattice structures and functionally graded materials.
Journal ArticleDOI
An investigation into reinforced and functionally graded lattice structures
Ian Maskery,Alexandra Hussey,Ajit Panesar,Adedeji Aremu,Christopher Tuck,Ian Ashcroft,Richard J.M. Hague +6 more
TL;DR: In this article, the authors investigated the crushing behaviour, mechanical properties and energy absorption of lattices made by an additive manufacturing process, including body-centred-cubic (BCC) and reinforced variant called BCCz.
Journal ArticleDOI
Undercut and overhang angle control in topology optimization: A density gradient based integral approach
TL;DR: In this paper, the authors present an approach for controlling the undercut and the minimal overhang angle in density-based topology optimization, which is useful for reducing support structures in additive manufacturing.
Topology Optimization for Additive Manufacturing
Abstract: This PhD thesis deals with the combination of topology optimization and additive manufacturing (AM, also known as 3D-printing). In addition to my own works, the thesis contains a broader review and assessment of the literature within the field. The thesis first presents a classification of the various AM technologies, a review of relevant manufacturing materials, the properties of these materials in the additively manufactured part, as well as manufacturing constraints with a potential for design optimization. Subsequently, specific topology optimization formulations relevant for the most important AM-related manufacturing constraints are presented. These constraints are divided into directional and non-directional constraints. Non-directional constraints include minimum/uniform length scale and a cavity constraint. It is shown that modified filter boundary conditions are required in order for the so-called robust formulation to ensure satisfaction of the minimum feature size in the vicinity of the design domain boundary. The most important directional constraint is a so-called overhang constraint. In relation to this, mainly two formulations from the literature are discussed. My own work has mainly been focused on better exploiting the new opportunities provided by AM. These are treated under the categories of multi-material applications, multi-scale approaches, and interface problems which incorporates elements from both of the preceding categories. It is shown how the material microstructure for a material with programmable, nearly constant Poisson’s ratio for large deformations may be designed and fabricated using direct ink writing. Structures are generated for the full interval [−0.8, 0.8], all with uniform feature size and a continuous print path, ensuring the potential for scalable manufacturing. In relation to interface problems it is shown how a flexible void area may be included into a standard minimum compliance problem by employing an additional design variable field and a sensitivity filter. Furthermore, it is shown how the design of coated structures may be modeled as a differentiable topology optimization problem. This is done partly by using spatial gradients of the density variable in the interpolation function between the design variable field and physical variables, partly by employing a two-step filtering scheme in order to control the gradient field. The approach is implemented for both 2D and 3D problems. A special case of this type of design problem is porous shell structures which are often used within AM. Based on numerical as well as experimental studies it is shown that such structures have a lower stiffness than fully solid structures, however, they possess significantly improved buckling properties and are less sensitive towards load perturbations. These properties are inherently ensured, that is, without the explicit definition of additional constraints.
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