A mold insert case study on topology optimized design for additive manufacturing

M. Sinico, R. Ranjan, M. Moshiri, C. Ayas, M. Langelaar, A. Witvrouw, F. van Keulen, W. Dewulf

    Research output: Chapter in Book/Report/Conference proceedingArticle in proceedingsResearchpeer-review

    Abstract

    The Additive Manufacturing (AM) of injection molding inserts has gained popularity during recent years primarily due to the reduced design-to-production time and form freedom offered by AM. In this paper, Topology Optimization (TO) is performed on a metallic mold insert which is to be produced by the Laser Powder Bed Fusion (LPBF) technique. First, a commercially available TO software is used, to minimize the mass of the component while ensuring adequate mechanical response under a prescribed loading condition. The commercial TO tool adopts geometry-based AM constraints and achieves a mass reduction of ~50 %. Furthermore, an in-house TO method has been developed which integrates a simplified AM process model within the standard TO algorithm for addressing the issue of local overheating during manufacturing. The two topology optimized designs are briefly compared, and the advantages of implementing manufacturing constraints into the TO algorithm are discussed.
    Original languageEnglish
    Title of host publicationProceedings of the 30th Annual International Solid Freeform Fabrication Symposium
    PublisherThe University of Texas at Austin
    Publication date2019
    Pages1921-1931
    Publication statusPublished - 2019
    Event30th Annual International Solid Freeform Fabrication Symposium - An Additive Manufacturing Conference (SFF 2019) - University of Texas at Austin, Austin, United States
    Duration: 12 Aug 201914 Aug 2019

    Conference

    Conference30th Annual International Solid Freeform Fabrication Symposium - An Additive Manufacturing Conference (SFF 2019)
    LocationUniversity of Texas at Austin
    Country/TerritoryUnited States
    CityAustin
    Period12/08/201914/08/2019
    SeriesSolid Freeform Fabrication Symposium Proceedings
    ISSN1053-2153

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