Topology Optimization of an Additively Manufactured Beam

This study investigates the application of topological optimization in conjunction with additive manufacturing (AM) process simulation for fabricating parts that meet strict quality and performance requirements while also minimizing printed geometry. Integrated Computational Materials Engineering (ICME) and GENOA 3D commercial software were used to simulate specimen fabrication and, along with commercial design optimization tools, create an optimized beam topology for simple loading conditions. Constraints were set in order to support any overhanging material with an appropriate inclination angle. These specimens were fabricated from Ti-6Al-4V using an EOS M290 direct metal laser sintering (DMLS) system with default parameters, as well as 95%, 90%, and 88% of default laser power in order to reduce the porosity in the overheated areas. Parts were subjected to X-ray CT scanning to quantify part porosity. It was determined that the process used allowed for the fabrication of specimens with optimized topology and minimal defects.