Optimization of Components with Topology Optimization for Direct Additive Manufacturing by DLMS

Area of Science:

• Mechanical Engineering
• Additive Manufacturing
• Computational Design

Background:

• Traditional design workflows often require extensive remodeling after topology optimization.
• Data transfer between design and simulation software can lead to errors and inefficiencies.
• Direct utilization of topology optimization results can significantly shorten product development cycles.

Purpose of the Study:

• To present a novel design methodology that directly uses topology optimization outputs as the final product shape.
• To streamline the design process by minimizing remodeling and eliminating data transfer issues.
• To reduce manufacturing errors through integrated process simulation.

Main Methods:

• Topology optimization was performed using Siemens NX Topology Optimization.
• Verification analysis was conducted using the NX Nastran solver.
• A case study involved designing a racing car steering column housing.
• The optimized part was fabricated using AlSi10Mg via direct metal laser sintering (D3 printing).

Main Results:

• The proposed methodology successfully integrated topology optimization with downstream manufacturing processes.
• The fabricated steering column housing met performance requirements during real-world validation.
• Remodeling steps and data import/export issues were eliminated, simplifying the workflow.

Conclusions:

• A comprehensive design methodology for direct utilization of topology optimization was developed and validated.
• The approach significantly enhances design efficiency and reduces potential manufacturing errors.
• This methodology offers a viable solution for rapid prototyping and production in demanding applications.