Name
Tech. Session XVI - 258
Date & Time
Friday, June 27, 2025, 10:30 AM - 10:55 AM
Description
Support structures are crucial to laser fusion metal
additive manufacturing processes for their capacity for
load bearing and heat transfer during the process. While
topology optimization has been extensively used to design
parts optimized for additive manufacturing, it has not been
extended to optimizing support structures to manage
distortion and tolerance errors. In this paper, based on
the thermal strains during the AM process, topology
optimization is applied to support structures to minimize
the distortion of flat features of the part geometry, thus
minimizing flatness form tolerance error while generating
minimal support structures that satisfy the self-support
criterion. The inherent strain method is used to calculate
the distortion from the additive manufacturing process, and
a density-based topology optimization scheme is developed,
where the adjoint method is used to derive sensitivities
for the distortion-based objective function. The algorithm
is applied to representative part geometries to create
minimal support structures while minimizing flatness errors
of planar features. The distortion obtained using the
generated supports resulted in less overall part distortion
and improved flatness errors compared to regular column
supports. This research presents a promising method for
optimizing support structures to minimize GD&T errors of
part features.
Location Name
Regency F
Full Address
Hyatt Regency
220 N Main St
Greenville, SC 29601
United States
220 N Main St
Greenville, SC 29601
United States
Session Type
Technical Session
Paper #
NAMRC 258
Author List
Navaneeth Chandran, Botao Zhang, Nathan Hertlein and Sam Anand
Paper Title
Topology Optimization of Support Structures for Additive Manufacturing to Minimize Distortion of Planar Surfaces and its Effect on Flatness Error
Presenter Name
Sam Anand
Session Chair
Sam Anand, Neha Choudhary
Presenter Email
anands@ucmail.uc.edu