Application of layout optimization to the design of additively manufactured metallic components

• Published in: Structural and multidisciplinary optimization Vol. 54; no. 5; pp. 1297 - 1313
• Main Authors: Smith, Christopher J., Gilbert, Matthew, Todd, Iain, Derguti, Fatos
• Format: Journal Article
• Language: English
• Published: Berlin/Heidelberg Springer Berlin Heidelberg 01.11.2016; Springer Nature B.V
• Subjects: Additive manufacturing; Computational Mathematics and Numerical Analysis; Design; Design optimization; Electron beam melting; Engineering; Engineering Design; Layouts; Mechanical properties; Post-processing; Research Paper; Theoretical and Applied Mechanics; Three dimensional printing; Titanium base alloys; Topology optimization; Topology optimization; EBM; 3D Printing; Additive manufacture; Layout optimization
• ISSN: 1615-147X; 1615-1488
• DOI: 10.1007/s00158-016-1426-1

Additive manufacturing (‘3D printing’) techniques provide engineers with unprecedented design freedoms, opening up the possibility for stronger and lighter component designs. In this paper ‘layout optimization’ is used to provide a reference volume and to identify potential design topologies for a given component, providing a useful alternative to continuum based topology optimization approaches (which normally require labour intensive post-processing in order to realise a practical component). Here simple rules are used to automatically transform a line structure layout into a 3D continuum. Two examples are considered: (i) a simple beam component subject to three-point bending; (ii) a more complex air-brake hinge component, designed for the Bloodhound supersonic car. These components were successfully additively manufactured using titanium Ti-6Al-4V, using the Electron Beam Melting (EBM) process. Also, to verify the efficacy of the process and the mechanical performance of the fabricated specimens, a total of 12 beam samples were load tested to failure, demonstrating that the target design load could successfully be met.