Analyzing the effects of void characteristics on the compliance of topology optimized structures for additive manufacturing
##plugins.themes.academic_pro.article.main##
Abstract
This study investigates the impact of void parameters, such as number, shape, and size, on the structural compliance of topology-optimized structures in additive manufacturing. The optimization uses the Sequential Element Rejection and Admission algorithm with a cantilever beam model subjected to a vertical load. Voids, modeled as elliptical regions with varying aspect ratios and saturations, are introduced into the optimized structure to simulate potential manufacturing defects. The influence of these void parameters on compliance is evaluated through finite element analysis, focusing on the relationship between void saturation, aspect ratio, and void size. The results indicate compliance increases with higher void saturations; the impact of void shape is more pronounced at high saturations. These findings provide insights into optimizing void characteristics for enhanced structural performance in additive manufacturing.
##plugins.themes.academic_pro.article.details##
This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License.
How to Cite
Benaissa, B., Al Ali, M., Khatir, B., & Saadatmorad, M. (2025). Analyzing the effects of void characteristics on the compliance of topology optimized structures for additive manufacturing. HCMCOU Journal of Science – Advances in Computational Structures, 15(1), 29–40. https://doi.org/10.46223/HCMCOUJS.acs.en.15.1.66.2025
References
- Al Ali, M., Shimoda, M., Benaissa, B., & Kobayashi, M. (2022). Concurrent multiscale hybrid topology optimization for light weight porous soft robotic hand with high cellular stiffness [Paper presentation]. International Conference of Steel and Composite for Engineering Structures, Lecce, Italy.
- Al Ali, M., Shimoda, M., Benaissa, B., Kobayashi, M., Takeuchi, T., Al-Shawk, A., & Ranjbar, S. (2024). Metaheuristic aided structural topology optimization method for heat sink design with low electromagnetic interference. Scientific Reports, 14(1), Aticle 3431.
- Behtani, A., Tiachacht, S., Khatir, T., Khatir, S., Wahab, M. A., & Benaissa, B. (2022). Residual force method for damage identification in a laminated composite plate with different boundary conditions. Frattura ed Integrità Strutturale, 16(59), 35-48.
- Benaissa, B., Al Ali, M., Kobayashi, M., Le, C. T., & Khatir, S. (2023). Damage tolerance in topologically optimized structures: Exploring structural integrity through worst-case damage optimization [Paper presentation]. International Conference of Steel and Composite for Engineering Structures, Lecce, Italy.
- Benaissa, B., Kobayashi, M., Al Ali, M., Khatir, S., & Shimoda, M. (2024). A novel exploration strategy for the YUKI algorithm for topology optimization with metaheuristic structural binary distribution. Engineering Optimization, 1-21.
- Brackett, D., Ashcroft, I., & Hague, R. (2011). Topology optimization for additive manufacturing. https://utw10945.utweb.utexas.edu/Manuscripts/2011/2011-27-Brackett.pdf
- Brahim, B., Kobayashi, M., Al Ali, M., Khatir, T., & Elmeliani, M. E. A. E. (2024). Metaheuristic optimization algorithms: An overview. HCMCOU Journal of Science-Advances in Computational Structures, 14(1), 34-62.
- Cantrell, J. T., Rohde, S., Damiani, D., Gurnani, R., DiSandro, L., Anton, J., Young, A., Jerez, A., Steinbach, D., Kroese, C., & Ifju, P. (2017). Experimental characterization of the mechanical properties of 3D-printed ABS and polycarbonate parts. Rapid Prototyping Journal, 23(4), 811-824.
- Dana, H. R., Barbe, F., Delbreilh, L., Azzouna, M. B., Guillet, A., & Breteau, T. (2019). Polymer additive manufacturing of ABS structure: Influence of printing direction on mechanical properties. Journal of Manufacturing Processes, 44, 288-298.
- Eiliat, H., & Urbanic, J. (2018). Visualizing, analyzing, and managing voids in the material extrusion process. The International Journal of Advanced Manufacturing Technology, 96, 4095-4109.
- Gaynor, A. T., & Johnson, T. E. (2020). Eliminating occluded voids in additive manufacturing design via a projection-based topology optimization scheme. Additive Manufacturing, 33, Article 101149.
- Harzheim, L., & Graf, G. (2006). A review of optimization of cast parts using topology optimization: II-Topology optimization with manufacturing constraints. Structural and Multidisciplinary Optimization, 31, 388-399.
- Hernandez-Contreras, A., Ruiz-Huerta, L., Caballero-Ruiz, A., Moock, V., & Siller, H. R. (2020). Extended CT void analysis in FDM additive manufacturing components. Materials, 13(17), Article 3831.
- Lee, H., Kim, J. H. J., Moon, J. H., Kim, W. W., & Seo, E. A. (2019). Correlation between pore characteristics and tensile bond strength of additive manufactured mortar using X-ray computed tomography. Construction and Building Materials, 226, 712-720.
- Lu, J., & Chen, Y. (2012). Manufacturable mechanical part design with constrained topology optimization. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 226(10), 1727-1735.
- Lynch, M. E., Mordasky, M., Cheng, L., & To, A. (2018). Design, testing, and mechanical behavior of additively manufactured casing with optimized lattice structure. Additive Manufacturing, 22, 462-471.
- Plocher, J., & Panesar, A. (2019). Review on design and structural optimisation in additive manufacturing: Towards next-generation lightweight structures. Materials & Design, 183, Article 108164.
- Rozvany, G., & Querin, O. (2002). Theoretical foundations of Sequential Element Rejections and Admissions (SERA) methods and their computational implementation in topology optimization [Paper presentation]. 9th AIAA/ISSMO Symposium on Multidisciplinary Analysis and Optimization, Washington, USA .
- Smith, C. J., Gilbert, M., Todd, I., & Derguti, F. (2016). Application of layout optimization to the design of additively manufactured metallic components. Structural and Multidisciplinary Optimization, 54, 1297-1313.
- Villarraga, H., Lee, C., Corbett, T., Tarbutton, J. A., & Smith, S. T. (2015). Assessing additive manufacturing processes with X-ray CT metrology [Paper presentation]. ASPE Spring Topical Meeting: Achieving Precision Tolerances in Additive Manufacturing, Raleigh, USA.
- Zhengkai, W., Wu, S., Qian, W., Zhang, H., Zhu, H., Chen, Q., Zhang, Z. X., Guo, F., Wang, J., & Withers, P. J. (2023). Structural integrity issues of additively manufactured railway components: Progress and challenges. Engineering Failure Analysis, 149, Article 107265.
- Zhou, L., & Zhang, W. (2019). Topology optimization method with elimination of enclosed voids. Structural and Multidisciplinary Optimization, 60, 117-136.
- Zhu, Z., Zhou, H., Wang, C., Zhou, L., Yuan, S., & Zhang, W. (2021). A review of topology optimization for additive manufacturing: Status and challenges. Chinese Journal of Aeronautics, 34(1), 91-110.