A method for designing a support structure for additive manufacturing based on multi-scale concurrent topology optimization

Abstract

This invention provides a design method for additive manufacturing lattice-filled support structures based on multi-scale concurrent topology optimization, belonging to the field of additive manufacturing and structural optimization design technology. Targeting the layer-by-layer forming and overhanging characteristics of additive manufacturing, this method uses the unit density of the support structure's topological layout as the design variable at the macro scale and the geometric parameters of the lattice unit cells as the design variable at the meso scale. A multi-scale concurrent optimization model is constructed with the objective of minimizing part deformation under comprehensive loading conditions, and volume fraction constraints, overhang retention constraints, and support removability constraints are introduced. Through the synergistic optimization of macro and meso design variables, the method achieves efficient solution to the multi-scale coupled optimization problem, obtaining a lattice-filled support structure that can effectively control part deformation and meet the requirements of additive manufacturing processes. This method is suitable for the design of support structures for large-scale complex parts, reducing manufacturing costs and enhancing engineering application value.

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