A topology optimization framework considering sintering in design for metal binder jetting additive manufacturing A topology optimization framework considering

• Published in: Structural and multidisciplinary optimization Vol. 68; no. 7
• Main Authors: Troelsgaard, Christian, Elmstrøm, Frederik Tobias, Lund, Erik
• Format: Journal Article
• Language: English
• Published: Berlin/Heidelberg Springer Berlin Heidelberg 23.07.2025
• Subjects: Computational Mathematics and Numerical Analysis; Engineering; Engineering Design; Research Paper; Theoretical and Applied Mechanics; Thermo-viscoplastic material; Sintering; Non-linear finite element; Topology optimization; Metal binder jetting; Path-dependent optimization; Additive manufacturing
• ISSN: 1615-147X; 1615-1488
• DOI: 10.1007/s00158-025-04059-y

This paper presents a novel method for reinforcing structures subject to sintering by topology optimization. The material is based on the Skorohod–Olevsky Viscous Sintering model with semi-implicit time integration. The design sensitivity analysis is based on the path-dependent adjoint method. A general framework is used, where objective functions can be implemented with minimal modification. In this work compliance, squared residuals and deviatoric work are implemented and compared. The analytical sensitivities are derived and rigorously verified. Comparison between the attained values proves the robustness and validity of the method. All terms used in the structural and design sensitivity analysis are supplied and therefore easily referenced and implemented for the reader. This method has the potential to allow for new possibilities in design for manufacturing considering sintering.