Topology Optimization

One of the greatest advantages of 3D printing is the ability to create objects with highly complex geometries. However, many designers are not yet able to think “additively” and design with shapes in mind that cannot be produced using traditional manufacturing methods. Fortunately, the enormous advances in CAD/CAE software in recent years have made this rapid transition to Additive Manufacturing easier.

Topology optimization is one of the most promising approaches in this regard. It provides guidance on the configuration of the load-bearing structure of a component intended to operate under specific structural and thermal loads.

The starting point is an overall volume within which the optimizer can work. The optimization calculation produces a map of the most important areas, as opposed to those whose contribution is negligible and can therefore be removed. This can reduce weight by as much as 60-70% while maintaining the same mechanical performance.

Thanks to our team, we were able to prototype our first object using an “additive” approach: a cold-room door handle.

After applying the loads and carrying out an FEM simulation (specifying the direction in which the print layers are stacked), we performed topology optimization, achieving a substantial reduction in weight while maintaining the target mechanical performance of the object (also taking into account the anisotropic behavior typical of objects produced using additive techniques). Below is a short gallery of images.