Multi-Objective Topology Optimization for Cost and Time Minimization in Fiber Reinforced Additive Manufacturing

Fiber Reinforced Additive Manufacturing (FRAM) combines the geometric freedom of additive manufacturing with the high strength-to-weight ratio of composite materials, enabling the production of lightweight, high-performance automotive components. The anisotropic nature of fiber-reinforced composites makes their mechanical performance highly dependent on fiber orientation relative to applied loads. Leveraging this directional behavior through optimization provides opportunities to enhance structural efficiency while reducing vehicle weight. Conventional FRAM research has largely focused on structural objectives such as compliance minimization, often overlooking manufacturability challenges. In particular, support structures - temporary features required for overhang fabrication - can significantly increase print time, material usage, and production cost, limiting industrial adoption. To address this gap, this research introduces a novel multi-objective topology optimization framework that simultaneously minimizes compliance and support structures by integrating Design for Additive Manufacturing (DfAM) principles directly into the optimization process. The methodology formulates support structure as a differentiable function of geometry and combines it with compliance minimization in a gradient-based framework. Validation using commercial slicing software confirmed strong correlation between predicted and actual support material volumes, as well as reductions in both print time and cost. These results demonstrate that substantial manufacturing savings can be achieved with only minimal trade-offs in structural performance. This work establishes a practical design framework for FRAM that unites performance-driven optimization with manufacturing efficiency. The approach reduces cost and build time while maintaining high structural integrity, demonstrating its potential to deliver lightweight, cost-effective composite components. These advancements highlight FRAM as a viable manufacturing pathway for next-generation automotive applications, where weight reduction, performance, and production efficiency are equally critical.