Topology optimisation for fused deposition modelling process

Abstract

Topology optimisation was conducted on a computer monitor stand model to achieve weight reduction while maintaining its structural integrity. Apart from optimising the topology of the model, lattice structure was also incorporated to leverage on the additive manufacturing (AM) technology in printing complex geometries that conventional manufacturing cannot produce. Lattice structure offers good stiffness-to-weight and strength-to-weight benefits which can be manufactured by AM. Maxwell’s criterion is employed to determine the rigidity of the lattice structure. Four different 2D lattice shapes, hexagonal, square, circle and square with diagonal strut will be incorporated separately into the model to investigate the effects of the lattices on deformation of the model. Finite element analysis (FEA) is conducted through computer software ANSYS Workbench to simulate loading and boundary conditions on the model. The model is printed via fused deposition modelling (FDM) technique which is one of the existing AM processes. Through this project, integration of topology optimisation and AM will help to save material usage and hence the material cost while still maintaining its functionality. Incorporation of lattice structure will further reduce more material used in fabrication of the model.