Chinese Journal of Lasers, Volume. 51, Issue 10, 1002307(2024)

Review of Self‑Supporting Design for Additive Manufacturing

Wei Wei1,2, Haixin Wu1,2, Xiaoxuan Wu1,2, Jindou Wu1,2, and Yu Long1,2、*
Author Affiliations
  • 1State Key Laboratory of Featured Metal Materials and Life-Cycle Safety for Composite Structures, Guangxi University, Nanning 530004, Guangxi, China
  • 2Institute of Laser Intelligent Manufacturing and Precision Processing, School of Mechanical Engineering, Guangxi University, Nanning 530004, Guangxi, China
  • show less
    References(78)

    [1] Zhu J H, Zhou H, Wang C et al. A review of topology optimization for additive manufacturing: status and challenges[J]. Chinese Journal of Aeronautics, 34, 91-110(2021).

    [2] Talagani M R, DorMohammadi S, Dutton R et al. Numerical simulation of big area additive manufacturing (3D printing) of a full sizes car[J]. SAMPE Journal, 51, 27-36(2015).

    [3] Lewis J A, Ahn B Y. Three-dimensional printed electronics[J]. Nature, 518, 42-43(2015).

    [4] Joshi S C, Sheikh A A. 3D printing in aerospace and its long-term sustainability[J]. Virtual and Physical Prototyping, 10, 175-185(2015).

    [5] Gu D D, Zhang H M, Chen H Y et al. Laser additive manufacturing of high-performance metallic aerospace components[J]. Chinese Journal of Lasers, 47, 0500002(2020).

    [6] Liaw C Y, Guvendiren M. Current and emerging applications of 3D printing in medicine[J]. Biofabrication, 9, 024102(2017).

    [7] Guest J K, Prévost J H, Belytschko T. Achieving minimum length scale in topology optimization using nodal design variables and projection functions[J]. International Journal for Numerical Methods in Engineering, 61, 238-254(2004).

    [8] Allaire G, Jouve F, Michailidis G. Thickness control in structural optimization via a level set method[J]. Structural and Multidisciplinary Optimization, 53, 1349-1382(2016).

    [9] Wang Y Q, Zhang L, Wang M Y. Length scale control for structural optimization by level sets[J]. Computer Methods in Applied Mechanics and Engineering, 305, 891-909(2016).

    [10] Liu J K, Li L, Ma Y S. Uniform thickness control without pre-specifying the length scale target under the level set topology optimization framework[J]. Advances in Engineering Software, 115, 204-216(2018).

    [11] Xia Q, Shi T L. Constraints of distance from boundary to skeleton: for the control of length scale in level set based structural topology optimization[J]. Computer Methods in Applied Mechanics and Engineering, 295, 525-542(2015).

    [12] Liu S T, Li Q H, Chen W J et al. An identification method for enclosed voids restriction in manufacturability design for additive manufacturing structures[J]. Frontiers of Mechanical Engineering, 10, 126-137(2015).

    [13] Xiong Y L, Yao S, Zhao Z L et al. A new approach to eliminating enclosed voids in topology optimization for additive manufacturing[J]. Additive Manufacturing, 32, 101006(2020).

    [14] Zhou L, Zhang W H. Topology optimization method with elimination of enclosed voids[J]. Structural and Multidisciplinary Optimization, 60, 117-136(2019).

    [15] Wang C, Xu B, Duan Z Y et al. Additive manufacturing-oriented stress minimization topology optimization with connectivity[J]. Chinese Journal of Theoretical and Applied Mechanics, 53, 1070-1080(2021).

    [16] Chen Q, Liang X, Hayduke D et al. An inherent strain based multiscale modeling framework for simulating part-scale residual deformation for direct metal laser sintering[J]. Additive Manufacturing, 28, 406-418(2019).

    [17] Zhang Z D, Ibhadode O, Ali U et al. Topology optimization parallel-computing framework based on the inherent strain method for support structure design in laser powder-bed fusion additive manufacturing[J]. International Journal of Mechanics and Materials in Design, 16, 897-923(2020).

    [18] Takezawa A, To A C, Chen Q et al. Sensitivity analysis and lattice density optimization for sequential inherent strain method used in additive manufacturing process[J]. Computer Methods in Applied Mechanics and Engineering, 370, 113231(2020).

    [19] Serphos M R. Incorporating AM-specific manufacturing constraints into topology optimization[D], 22(2014).

    [20] Meng L, Zhang W H, Quan D L et al. From topology optimization design to additive manufacturing: today’s success and tomorrow’s roadmap[J]. Archives of Computational Methods in Engineering, 27, 805-830(2020).

    [23] Zhang J Z, Tang H L, Wang C et al. Latest research progress and prospect of process planning algorithms of multiaxis support-free 3D printing for complex structure[J]. Chinese Journal of Lasers, 49, 1402302(2022).

    [24] Liu S T, Li Q H, Chen W J et al. Combination of topology optimization and additive manufacturing: an integration method of structural design and manufacturing[J]. Aeronautical Manufacturing Technology, 60, 26-31(2017).

    [25] Liu B Y, Wang X M, Yang G et al. Research progress on topology optimization design for metal additive manufacturing[J]. Chinese Journal of Lasers, 50, 1202301(2023).

    [26] Wang D, Yang Y Q, Yi Z H et al. Research on the fabricating quality optimization of the overhanging surface in SLM process[J]. The International Journal of Advanced Manufacturing Technology, 65, 1471-1484(2013).

    [27] Mertens R, Clijsters S, Kempen K et al. Optimization of scan strategies in selective laser melting of aluminum parts with downfacing areas[J]. Journal of Manufacturing Science and Engineering, 136, 061012(2014).

    [28] Kranz J, Herzog D, Emmelmann C. Design guidelines for laser additive manufacturing of lightweight structures in TiAl6V4[J]. Journal of Laser Applications, 27, S14001(2015).

    [30] Langelaar M. An additive manufacturing filter for topology optimization of print-ready designs[J]. Structural and Multidisciplinary Optimization, 55, 871-883(2017).

    [31] Langelaar M. Topology optimization of 3D self-supporting structures for additive manufacturing[J]. Additive Manufacturing, 12, 60-70(2016).

    [32] Sigmund O. A 99 line topology optimization code written in Matlab[J]. Structural and Multidisciplinary Optimization, 21, 120-127(2001).

    [33] Bendsøe M P, Sigmund O[M]. Topology optimization: theory, methods, and applications(2003).

    [34] Leary M, Merli L, Torti F et al. Optimal topology for additive manufacture: a method for enabling additive manufacture of support-free optimal structures[J]. Materials & Design, 63, 678-690(2014).

    [35] Brackett D, Ashcroft I, Hague R. Topology optimization for additive manufacturing[C](2011).

    [36] Gaynor A T, Meisel N A, Williams C B et al. Topology optimization for additive manufacturing: considering maximum overhang constraint[C], 2036(2014).

    [37] Garaigordobil A, Ansola R, Santamaría J et al. A new overhang constraint for topology optimization of self-supporting structures in additive manufacturing[J]. Structural and Multidisciplinary Optimization, 58, 2003-2017(2018).

    [38] Kuo Y H, Cheng C C. Self-supporting structure design for additive manufacturing by using a logistic aggregate function[J]. Structural and Multidisciplinary Optimization, 60, 1109-1121(2019).

    [40] Fu Y F, Rolfe B, Chiu L N S et al. Design and experimental validation of self-supporting topologies for additive manufacturing[J]. Virtual and Physical Prototyping, 14, 382-394(2019).

    [41] Fu Y F, Rolfe B, Chiu L N S et al. Parametric studies and manufacturability experiments on smooth self-supporting topologies[J]. Virtual and Physical Prototyping, 15, 22-34(2020).

    [42] Wang C, Zhang W H, Zhou L et al. Topology optimization of self-supporting structures for additive manufacturing with B-spline parameterization[J]. Computer Methods in Applied Mechanics and Engineering, 374, 113599(2021).

    [43] Ambrozkiewicz O, Kriegesmann B. Density-based shape optimization for fail-safe design[J]. Journal of Computational Design and Engineering, 7, 615-629(2020).

    [44] Wu Z J, Xiao R B. A topology optimization approach to structure design with self-supporting constraints in additive manufacturing[J]. Journal of Computational Design and Engineering, 9, 364-379(2022).

    [45] Ye J, Guo Q C, Lu H J et al. Topology optimisation of self-supporting structures based on the multi-directional additive manufacturing technique[J]. Virtual and Physical Prototyping, 18, e2271458(2023).

    [46] Sethian J A, Wiegmann A. Structural boundary design via level set and immersed interface methods[J]. Journal of Computational Physics, 163, 489-528(2000).

    [47] Liu J K, To A C. Deposition path planning-integrated structural topology optimization for 3D additive manufacturing subject to self-support constraint[J]. Computer-Aided Design, 91, 27-45(2017).

    [48] Wang Y G, Gao J C, Kang Z. Level set-based topology optimization with overhang constraint: towards support-free additive manufacturing[J]. Computer Methods in Applied Mechanics and Engineering, 339, 591-614(2018).

    [49] Liu J K, Yu H C. Self-support topology optimization with horizontal overhangs for additive manufacturing[J]. Journal of Manufacturing Science and Engineering, 142, 091003(2020).

    [50] Allaire G, Dapogny C, Estevez R et al. Structural optimization under overhang constraints imposed by additive manufacturing technologies[J]. Journal of Computational Physics, 351, 295-328(2017).

    [51] Han Y S, Xu B, Zhao L et al. Topology optimization of continuum structures under hybrid additive-subtractive manufacturing constraints[J]. Structural and Multidisciplinary Optimization, 60, 2571-2595(2019).

    [52] Bi M H, Tran P, Xie Y M. Topology optimization of 3D continuum structures under geometric self-supporting constraint[J]. Additive Manufacturing, 36, 101422(2020).

    [53] Guo X, Zhou J H, Zhang W S et al. Self-supporting structure design in additive manufacturing through explicit topology optimization[J]. Computer Methods in Applied Mechanics and Engineering, 323, 27-63(2017).

    [54] Zhang W H, Zhou L. Topology optimization of self-supporting structures with polygon features for additive manufacturing[J]. Computer Methods in Applied Mechanics and Engineering, 334, 56-78(2018).

    [55] Zhou L, Sigmund O, Zhang W H. Self-supporting structure design with feature-driven optimization approach for additive manufacturing[J]. Computer Methods in Applied Mechanics and Engineering, 386, 114110(2021).

    [56] Mass Y, Amir O. Topology optimization for additive manufacturing: accounting for overhang limitations using a virtual skeleton[J]. Additive Manufacturing, 18, 58-73(2017).

    [57] He L W, Gilbert M, Johnson T et al. Conceptual design of AM components using layout and geometry optimization[J]. Computers & Mathematics with Applications, 78, 2308-2324(2019).

    [58] Hu K L, Jin S, Wang C C L. Support slimming for single material based additive manufacturing[J]. Computer-Aided Design, 65, 1-10(2015).

    [59] Liu Y C, Zhou M D, Wei C. Topology optimization of self-supporting infill structures[C], 1(2022).

    [60] Xu W P, Miao L T, Liu L G. Review on structure optimization in 3D printing[J]. Journal of Computer-Aided Design & Computer Graphics, 29, 1155-1168(2017).

    [61] Wu J, Wang C C L, Zhang X T et al. Self-supporting rhombic infill structures for additive manufacturing[J]. Computer-Aided Design, 80, 32-42(2016).

    [62] Wang W M, Qian S C, Lin L P et al. Support-free frame structures[J]. Computers & Graphics, 66, 154-161(2017).

    [63] Martínez J, Hornus S, Song H C et al. Polyhedral Voronoi diagrams for additive manufacturing[J]. ACM Transactions on Graphics, 37, 129(2018).

    [64] Kuipers T, Wu J, Wang C C L. CrossFill: foam structures with graded density for continuous material extrusion[J]. Computer-Aided Design, 114, 37-50(2019).

    [65] Xu W P, Liu Y, Yu M L et al. A support-free infill structure based on layer construction for 3D printing[J]. IEEE Transactions on Visualization and Computer Graphics, 28, 4462-4476(2022).

    [66] Wu J, Aage N, Westermann R et al. Infill optimization for additive manufacturing-approaching bone-like porous structures[J]. IEEE Transactions on Visualization and Computer Graphics, 24, 1127-1140(2018).

    [67] Lee M, Fang Q, Cho Y et al. Support-free hollowing for 3D printing via Voronoi diagram of ellipses[J]. Computer-Aided Design, 101, 23-36(2018).

    [68] Xu W P, Zhang P, Liu Y et al. Self-supporting connectable filling structure design for 3D printing[J]. Journal of Computer-Aided Design & Computer Graphics, 35, 155-164(2023).

    [69] Liu Y C, Zhou M D, Wei C et al. Topology optimization of self-supporting infill structures[J]. Structural and Multidisciplinary Optimization, 63, 2289-2304(2021).

    [70] Zhou M D, Lu Y F, Liu Y C et al. Concurrent topology optimization of shells with self-supporting infills for additive manufacturing[J]. Computer Methods in Applied Mechanics and Engineering, 390, 114430(2022).

    [71] Zou J, Zhang Y C, Feng Z Y. Topology optimization for additive manufacturing with self-supporting constraint[J]. Structural and Multidisciplinary Optimization, 63, 2341-2353(2021).

    [72] Zhang K Q, Cheng G D, Xu L. Topology optimization considering overhang constraint in additive manufacturing[J]. Computers and Structures, 212, 86-100(2019).

    [73] Wang Y, Xia J J, Luo Z et al. Self-supporting topology optimization method for selective laser melting[J]. Additive Manufacturing, 36, 101506(2020).

    [74] Zou J, Mou H L. Topology optimization of self-supporting structures for additive manufacturing with adaptive explicit continuous constraint[J]. Computer Modeling in Engineering & Sciences, 132, 451-469(2022).

    [75] Li Z H, Zhang D Z, Dong P et al. A lightweight and support-free design method for selective laser melting[J]. The International Journal of Advanced Manufacturing Technology, 90, 2943-2953(2017).

    [76] Li Z H, Zhang D Z, Dong P et al. Incorporating draw constraint in the lightweight and self-supporting optimisation process for selective laser melting[J]. The International Journal of Advanced Manufacturing Technology, 98, 405-412(2018).

    [77] Xu S Z, Liu J K, Ma Y S. Residual stress constrained self-support topology optimization for metal additive manufacturing[J]. Computer Methods in Applied Mechanics and Engineering, 389, 114380(2022).

    [78] Miki T. Self-support topology optimization considering distortion for metal additive manufacturing[J]. Computer Methods in Applied Mechanics and Engineering, 404, 115821(2023).

    Tools

    Get Citation

    Copy Citation Text

    Wei Wei, Haixin Wu, Xiaoxuan Wu, Jindou Wu, Yu Long. Review of Self‑Supporting Design for Additive Manufacturing[J]. Chinese Journal of Lasers, 2024, 51(10): 1002307

    Download Citation

    EndNote(RIS)BibTexPlain Text
    Save article for my favorites
    Paper Information

    Category: Laser Additive Manufacturing

    Received: Jan. 2, 2024

    Accepted: Mar. 18, 2024

    Published Online: Apr. 27, 2024

    The Author Email: Long Yu (longyu@gxu.edu.cn)

    DOI:10.3788/CJL240434

    Topics