Compression performance of hollow structures: From topology optimisation to design 3D printing

• Published in: International journal of mechanical sciences Vol. 133; pp. 728 - 739
• Main Authors: Belhabib, Sofiane, Guessasma, Sofiane
• Format: Journal Article
• Language: English
• Published: Elsevier Ltd 01.11.2017; Elsevier
• Subjects: Compression testing; Engineering Sciences; Finite element method; Fused deposition modelling; Hollow structure; Materials; Topology optimisation; Finite element method; Hollow structure; Compression testing; Topology optimisation; Fused deposition modelling
• ISSN: 0020-7403; 1879-2162
• DOI: 10.1016/j.ijmecsci.2017.09.033

•Inequivalent designs from CAD-based topology optimisation for additive manufacturing.•Filament-based simulation explains differences between FDM-based hallow designs.•Anisotropic space filling offers potential to tune hallow designs performance. In this work, we experimentally evaluate the rendering of topology optimisation through the design of hollow structures manufactured using a 3D printing technique. The moving asymptote method is used as a mathematical optimisation strategy to virtually minimise the volume of 2D designs subject to hydrostatic pressure by half. Designs are converted to 3D models by extrusion in the building direction and printed using the Fused Deposition Modelling technique. Compression testing up to densification is performed and designs are evaluated. The results show that extrusion of the design in the building direction provides the best option to avoid mechanical anisotropy induced by processing. Depending on the type and extent of excluded regions, mechanical performance proves to be adapted to a wide range of designs and different types of mechanical anisotropies can be derived. Comparison with finite element results shows differences in behaviour related to mechanical instabilities that occur as a result of the lack of inter-filament cohesion and external frame unsoldering. [Display omitted]