Application of topology optimization and design for additive manufacturing guidelines on an automotive component

Topology optimization is a well-established engineering practice to optimize the design and layout of parts to create lightweight and low-cost structures, which have historically been difficult, or impossible, to make. Additive Manufacturing (AM) provides the freedom to fabricate the complex and organic shapes that topology optimization often generates. In this paper we use topology optimization to create lightweight designs while conforming to additive manufacturing constraints related to overhanging features and unsupported surfaces when using metallic materials. More specifically, we use design for additive manufacturing (DfAM) rules along with topology optimization to study the tradeoffs between the weight of the part, support requirements, manufacturing costs, and performance. The case study entails redesigning an upright on the SAE Formula student racecar to reduce support structures and manufacturing and material cost when using Direct Metal Laser Sintering (DMLS). Manufacturing the optimized design without applying DfAM rules required support material up to 202.4% of the volume of the model. Using DfAM, the upright is redesigned and manufactured with supports requiring less than 15% of the volume of the model. The results demonstrate the challenges in achieving a balance between weight reduction, manufacturing costs, and factor of safety of the design.