Rules, precursors and parameterization methodologies for topology optimized structural designs realized through additive manufacturing

Additive manufacturing, more commonly known as 3D printing is a rapidly developing, thoroughly novel means of producing complex, previously difficult to manufacture components. Slowly divorcing itself from previously held preconceptions of rapid prototyping and now capable of producing comparable structures from materials such as titanium and high strength nickel alloys, it is a means of manufacturing structures deemed too complex for existing fabrication techniques. Whilst free of conventional constraints, the unique intricacies of the manufacturing process can lead to the creation of factors, detrimental to production success. The research detailed within this paper demonstrates through example, how the orientation of a part prior to build can be optimized in order to significantly mitigate these effects and to maximize build economics. Furthermore the research details a new method for the combined assessment and tailored structural topology optimization of parts intended for production by specific additive manufacturing technologies.