Optimized One-Click Development for Topology-Optimized Structures

• Main Authors: Tobias Rosnitschek, Rick Hentschel, Tobias Siegel, Claudia Kleinschrodt, Markus Zimmermann, Bettina Alber-Laukant, Frank Rieg
• Format: Article
• Language: English
• Published: MDPI AG 2021-03-01
• Series: Applied Sciences
• Subjects: additive manufacturing; automated product development; design automation; design for additive manufacturing; lightweight engineering; manufacturing constraints
• Online Access: https://www.mdpi.com/2076-3417/11/5/2400

Topology optimization is a powerful digital engineering tool for the development of lightweight products. Nevertheless, the transition of obtained design proposals into manufacturable parts is still a challenging task. In this article, the development of a freeware framework is shown, which uses a hybrid topology optimization algorithm for stiffness and strength combined with manufacturing constraints based on finite spheres and a two-step smoothing algorithm to design manufacturable prototypes with “one click”. The presented workflow is shown in detail on a rocker, which is “one-click”-optimized and manufactured. These parts were experimentally tested using a universal testing machine. The objective of this article was to investigate the performance of “one-click”-optimized parts in comparison with manually redesigned optimized parts and the initial design space. The test results show that the design proposals created while applying the finite-spheres and two-step smoothing are equal to the manual redesigned parts based on the optimization results, proposing that the “one-click”-development can be used for the fast and direct development and fabrication of prototypes.