Self-support topology optimization considering distortion and overheating for metal additive manufacturing

This study proposes a self-support topology optimization method that considers distortion and overheating to improve the manufacturability of additive manufacturing. First, a self-support constraint is proposed that combines an overhang angle constraint with an adjustable degree of the dripping effect and a thermal constraint for heat dissipation in the building process. Next, we introduce a mechanical model based on the inherent strain method in the building process and propose a constraint that can suppress distortion. A multi-objective optimization problem is formulated to satisfy all constraints, and an optimization algorithm based on level-set-based topology optimization is constructed. Finally, two- and three-dimensional optimization examples are presented to validate the effectiveness of the proposed topology optimization method.