FRAM Optimization: 3D Print Orientation and Concurrent Topology Optimization for Minimize Mass Problem Statements

Fiber reinforced additive manufacturing (FRAM) is a fused deposition modelling (FDM) additive manufacturing (AM) process which produces composite print layers - polymer matrix and reinforcing fiber. This work proposes a novel method which utilizes FRAM design freedom and simultaneously optimizes 3D print orientation and component topology to improve the response of a mass minimization problem statement. The method is robust and is designed to solve industry-applicable problem statements (mass minimization) with complex geometry and loading. Design sensitivities of 3D print orientation design variables, (θ₁, θ₂, θ₃), are calculated using finite differencing and gradient descent is used to converge to an optimized print orientation. Changing 3D print orientation alters anisotropic material properties to improve the structural response of the component in the prescribed load-cases. The numerical method optimizes the anisotropic material properties of the component and concurrently optimizes topology within the anisotropic state. The method is applied to a case study: a mass minimization problem statement subject to four displacement constraints. Print orientation is iteratively altered, improving response of the displacement constraints by optimizing anisotropic material properties for the applied load-cases of the component. Optimized topology of the component is re-established at each iteration, improving the mass minimization objective function as a result of the print orientation optimization. The solution of the case study is compared to alternative FRAM and metallic solutions to demonstrate the capabilities of the proposed method.