Lattice structures grading for stiffness optimization: An approach based on topology optimization for parts manufactured via multi jet fusion

Abstract

The rapid advancement of additive manufacturing (AM) technology and computational design techniques has unveiled a promising synergy between these two fields. The high print resolution achievable nowadays enables the pro-duction of intricate shapes, such as lattice structures, which can be further optimized through simulation-driven design techniques such as topology optimization (TO). This paper presents an optimization workflow that leverages field-driven design to employ the results of a TO to locally vary the diameter of lattice structures, aiming for weight reduction and stiffness maximization. The process involves the automation of nTop design software via Python scripts to systematically evaluate design variants and identify optimal solutions. The workflow steps are demonstrated through the application to a connecting rod and conclude with the evaluation of the achieved mechanical performance of the optimized component via Finite Element Method (FEM) analysis.