Non-Linear Filtering for Local Minimum Length and Overhang Control in Topology Optimization

  • Torres, Jose (CIMNE - UPC)
  • Esmail, Mohamed (TUM)
  • Otero, Fermin (CIMNE - UPC)
  • Ferrer, Alex (CIMNE - UPC)

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A key challenge currently facing the transport industry is the development of new lightweight materials designed to reduce fuel consumption and minimize environmental impact. This can be accomplished, for instance, by introducing new types of complex microstructures. Topology optimization techniques facilitate weight reduction while simultaneously minimizing design time and cost. Nevertheless, these methods often yield complex designs that can only be fabricated through additive manufacturing. Consequently, numerical optimization must be integrated with 3D printing constraints to ensure manufacturability, including considerations such as minimal length scale and overhang control, thereby preventing the formation of complex shapes and volumes. The objective of this study is to examine the feasibility of optimal design while incorporating minimum length and overhang constraints specific to the additive manufacturing process. We propose the use of non-linear filters to penalize overhangs in the context of 3D printing, while simultaneously ensuring an appropriate length scale in the opposite direction. Additionally, this smoothing technique is combined with the concept of local perimeter to address 3D printing constraints in a more localized manner. The results indicate that local bars with small length scales are eliminated, and a vertical orientation of the bars is achieved.