Explorations of optimal layouts for planar elements

This research proposes an ad-hoc numerical procedure for the topology optimization (TO) of WAAM-produced planar elements. In particular, the procedure is based on traditional TO algorithms implemented for WAAM stainless steel, to account for the orthotropic nature. 

As such, a simultaneous layout optimization and printing orientation can be suitably estimated for planar elements. The results evidence the influence of the printing orientation on the optimal layouts, with further volume reduction on suitable orientations.

The optimized solutions for 2D simply-supported beam are then applied for the case of a I-type beam. Indeed, the web corresponds to the most suitable solution of the 2D case, while the flanges are shaped based on traditional static analysis considerations. 

The proposed tool can be conveniently used to save weight by adopting WAAM process to create customized optimal solutions for any design domain, load conditions and restraint configurations. Further explorations on more complex shapes are currently under development.

References

Bruggi, M., Laghi, V., & Trombetti, T. (2021). Simultaneous design of the topology and the build orientation of Wire-and-Arc Additively Manufactured structural elements. Computers & Structures, 242, 106370.