Systematical redesign method for topology optimized results using 3D-printing

Abstract

Abstract3D-Printing enables designers to create parts with higher geometric complexity and gives them the opportunity to use new design methods such as topology optimization for industrial purpose. Topology optimization (TO) uses algorithms based on finite elements to provide the best material distribution for a given design space and defined boundary conditions. However, raw TO results are usually inconsistent and non-continuous structures that need to be redesigned. Since the smoothing tools and algorithms available on TO software programs are not covering all manufacturing aspects, this paper presents a strategy for interpreting and redesigning the optimized topology using five defined sub-structure elements. Several TO structures from the literature have been studied in order to choose those sub-structure elements that can fully describe any TO result. The approach called KS2 (Knoten-Stab-Schubfeld) ensures an efficient workflow. Three different reconstruction methods are considered in this work, from a manual to a fully automated one. The advantages and drawbacks of each method are discussed, and a systematic procedure is suggested, that can be applied on any optimized structure. Finally, the three variations were produced by means of 3d printing and compared with each other.