Shape optimization for composite polymers in 3D printing

Topology Optimization is an effective method of minimising waste and optimising the structural design of the objects. 3D printing is one of the modern manufacturing technologies that can be significantly improved by implementing the topology optimization of printed objects. Geometry optimization in manufacturing technologies can eliminate the unnecessary parts of the 3D printed objects that are not affected by loads, stresses and strains. Therefore, implementing this technique can result in a significant reduction of waste materials and production costs. In this paper, shape optimization by the Layer-by-Layer (LbL) method and shape optimization by Homogenization of composite materials are discussed. The computational analysis was conducted by specifically designing specimens for the tensile load and obtaining the optimized shape for each design. These flat plates have similar shapes, but different compositions. The first method proposes the development of a composite structure by the Layer-by-Layer method and then applies the topology optimization process. The second method focuses on the development of a homogeneous composite structure by the computation of mechanical properties, which is then followed by implementing the topology optimization method based on ANSYS simulation. The main aim of this work is to compare and select the best shape optimization technique for the reduction of materials used in 3D printing.