Self-support topology optimization considering distortion for metal additive manufacturing.

This paper proposes a self-support topology optimization method that considers distortion 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 downward convex shapes 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. An 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. • A new self-support constraint based on the level-set-based topology optimization is proposed. • A distortion constraint in additive manufacturing (AM) based on the inherent strain method is formulated. • Self-support topology optimization considering distortion for metal AM is proposed. • Optimized designs satisfy each constraint without much loss of structural performance. [ABSTRACT FROM AUTHOR]