Topology Optimization Design Method of Self-supported Structures in Additive Manufacturing Based on Residual Deformation Control

doi:10.3901/JME.260260

Abstract

Abstract: Residual deformation is a critical factor causing cracking and failure in additively manufactured components. This study proposes a self-supported structure design method for additive manufacturing that simultaneously considers residual deformation and overhang angle constraints during the design phase. First, the residual deformation of the printed component is predicted based on the inherent strain method. A layered steady-state heat transfer model is established to investigate the influence of overhang angle on component temperature, with maximum temperature constraints introduced to satisfy overhang angle requirements. Taking structural compliance and weighted minimization of residual deformation as optimization objectives, and using maximum temperature and volume fraction as constraints, topology optimization design is implemented through the density method. The effectiveness of the proposed method is validated through representative case studies of cantilever beams and L-shaped beams. Results demonstrate that the optimized structure exhibits significantly reduced maximum residual deformation compared to conventional designs while meeting overhang angle requirements and aligning with self-supported design principles. When the component’s printing direction coincides with the force transmission path direction, maximum residual deformation can be effectively reduced and structural stiffness enhanced. Increasing the layer thickness of the heat transfer model facilitates the generation of fine branches, thereby improving heat transfer to the substrate. The proposed design method provides technical guidance for additive manufacturing of complex structures.

Key words: additive manufacturing, residual deformation, topology optimization, overhang angle constraint, self-supported structure

CLC Number:

TH122

YANG Jiandong, DING Xiaohong, XIONG Min, ZHANG Heng. Topology Optimization Design Method of Self-supported Structures in Additive Manufacturing Based on Residual Deformation Control[J]. Journal of Mechanical Engineering, 2026, 62(15): 555-565.

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URL: http://www.cjmenet.com.cn/EN/10.3901/JME.260260

http://www.cjmenet.com.cn/EN/Y2026/V62/I15/555

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