Topology Optimisation for Structural Integrity: Improving Part Quality and Performance within the Design-for-Additive-Manufacture Work Flow

Increasingly, topology optimisation is being used to design and create complex, innovative, and structurally-efficient designs that can be produced by additive manufacturing processes. However, consideration of the manufacturability, functionality and integrity requirements of the part often means that the results of a topology optimisation simulation are unsuitable for immediate production. In this work, the current technology gap between design-for-function and design-for-manufacture is explored, with a series of examples that highlight the limitations and risks within existing design optimisation work flows. Particular attention is given to optimising a part with respect to a series of objectives including weight, normal operating conditions, fatigue endurance, misuse or overloads, costs, quality and manufacturability.