A new algorithm for design of support structures in additive manufacturing by using topology optimization

In this paper, a density based topology optimization is proposed for generating of supports required in additive manufacturing to maintain the overhanging regions of main structures during layer by layer fabrication process. For this purpose, isogeometric analysis method is employed to model geometry and structural analysis of main and support structures. In order to model the problem two cases are investigated. In the first case, design domain of supports can easily be separated from the main structure by using distinct isogeometric patches. The second case happens when the main structure itself is optimized by using topology optimization and the supports should be designed in the voids of optimum layout. In this case, in order to avoid boundary identification and re-meshing process for separating design domain of supports from main structure, a parameterization technique is proposed to identify the design domain of supports. To achieve this, two density functions are defined over the entire domain to describe the main structure and supporting areas. On the other hand, since supports are under gravity loads while main structure and its stiffness is not completed during manufacturing process, in the proposed method, stiffness of the main structure is considered to be trivial and the gravity loads are also naturally applied to design support structures. By doing so, the results show reasonable supports are created to protect, continuously, overhanging surfaces of the main structure. Several examples are presented to demonstrate the efficiency of the proposed method and compare the results with literature.