Topology optimization of supports with imperfect bonding in additive manufacturing

Grégoire Allaire (1) , Beniamin Bogosel (1) , Matías Godoy (1, 2)

1 CMAP - Centre de Mathématiques Appliquées - Ecole Polytechnique
2 CNRS - Centre National de la Recherche Scientifique

Supports are an important ingredient of the building process of structures by additive manufacturing technologies. They are used to reinforce overhanging regions of the desired structure and/or to facilitate the mitigation of residual thermal stresses due to the extreme heat flux produced by the source term (laser beam). Very often, supports are, on purpose, weakly connected to the built structure for easing their removal. In this work we consider an imperfect interface model for which the interaction between supports and the built structure is not ideal, meaning that the displacement is discontinuous at the interface while the normal stress is continuous and proportional to the jump of the displacement. The optimization process is based on the level set method, body fitted meshes and the notion of shape derivative using the adjoint method. We provide 2-d and 3-d numerical examples, as well as a comparison with the usual perfect interface model. Completely different designs of supports are obtained with perfect or imperfect interfaces.

Mots clés: Imperfect interface; interfacial rigidity; support optimization; topology optimization; level set method

Domaines: Optimisation et contrôle [math.OC]

Grégoire Allaire, Beniamin Bogosel, Matías Godoy. Topology optimization of supports with imperfect bonding in additive manufacturing. 2022. ⟨hal-03538224v1⟩