Topology optimization with additive manufacturing consideration for vehicle load path development

Topology optimization has been widely studied and implemented as a powerful conceptual design tool in various engineering applications. However, the result from topology optimization has posed an implementation challenge to engineers because of the complexity of converting obtained solution into computer-aided design data and then fabricating it into real parts. Over the past few years, the advanced additive manufacturing technology with new materials and higher resolution output capabilities has opened numerous opportunities to fill the gap between topology optimization and product application. In this study, an engineering procedure is presented for the conversion of topology optimization result to ready-to-print model for additive manufacturing. The steps of post-optimization handling are outlined, and the potential practical issues for the additive manufacturing implementation are discussed. A vehicle example for full frontal impact load path development by topology optimization with inertia relief approach is used to exhibit the employed additive manufacturing implementation process with a reduced-scale part build. The arising implementation issues and needs are examined for future advance of topology optimization and additive manufacturing integration development.