Concurrent high-resolution topology optimization of structures and their supports for additive manufacturing

This paper presents a layered construction approach for embedding the overhang limitation and support structure requirement in topology optimization. This approach accounts for layer-by-layer construction stages, by minimizing the compliance due to body forces together with the compliance of the final loading situation. Hence, deformation caused by body forces is minimized by generating self-supporting structures. Three parameterizations are investigated that correspond to the distribution of solid and void; the distribution of a homogenized lattice meta-material that covers the complete density range; and a two-material scheme where two material phases are distributed simultaneously, one is a continuum solid-void and the other is a homogenized lattice that acts as additional support structure. Even with little additional support material, the two-material parameterization demonstrates significant reduction of overhang violation with negligible compromise of the structural performance. By manipulating the parameters of the layered construction, such as the layer-wise resolution and the weighting factors, further improvement is achieved. The procedures are implemented in a parallel computing environment and are fully scalable, hence suitable for modern high-resolution topology optimization.