Topology Optimisation of Additively Manufactured Lattice Beams for Three-Point Bending Test

The ability of additive manufacturing to develop parts with complex shapes has increased the bandwidth of product design. This has facilitated the use of Topology Optimisation (TO) techniques to optimise the distribution of material throughout the part, thereby obtaining minimum weight without compromising the mechanical performance of the component. In this study the Bi-directional Evolutionary Structural Optimisation (BESO) algorithm was used to generate topologically optimised lattice unit cells. A simple bending beam with 50% reduced volume was printed in two different unit cell arrangements using Selective Laser Melting (SLM) process. Prior to printing, the density of SLM-printed AlSi12 samples was enhanced by using appropriate scanning strategy. The flexural properties of these topology optimised beams were compared with the solid beam. The topologically optimised beams absorbed about seven times more energy per unit volume till the displacement of maximum bending load when compared with the solid beam at the same displacement.