Direction-Oriented Stress-Constrained Topology Optimization of 3D Printed Polymers

Efficient optimization of topology and raster angle has shown unprecedented enhancements in the mechanical properties of 3D printed thermoplastic polymers. Topology optimization helps reduce the waste of raw material in the fabrication of 3D printed parts, thus decreasing production costs associated with manufacturing lighter structures. Fiber orientation plays an important role in increasing the stiffness of a structure. This paper develops and tests a new method for handling stress constraints in topology and fiber orientation optimization of 3D printed orthotropic structures. The stress constraints are coupled with an objective function that maximizes stiffness. This is accomplished by using the modified solid isotropic material with penalization method with the method of moving asymptotes as the optimizer. Each element has a fictitious density and an angle as the main design variables. To reduce the number of stress constraints and thus the computational cost, a new clustering strategy is employed in which the highest stresses in the principal material coordinates are grouped separately into two clusters using an adjusted $P$-norm. A detailed description of the formulation and sensitivity analysis is discussed. While we present an analysis of 2D structures in the numerical examples section, the method can also be used for 3D structures, as the formulation is generic. Our results show that this method can produce efficient structures suitable for 3D printing while avoiding stress concentrations.