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Fiber reinforced additive manufacturing (FRAM) is an emerging technology that combines additive manufacturing and composite materials. As a result, design freedom offered by the manufacturing process can be leveraged in design optimization. The purpose of the study is to propose a novel method that improves structural performance by optimizing 3D print orientation of FRAM components.

This work proposes a two-part design optimization method that optimizes 3D global print orientation and topology of a component to improve a structural objective function. The method considers two classes of design variables: (1) print orientation design variables and (2) density-based topology design variables. Print orientation design variables determine a unique 3D print orientation to influence anisotropic material properties. Topology optimization determines an optimal distribution of material within the optimized print orientation.

Two academic examples are used to demonstrate basic behavior of the method in tension and shear. Print orientation and sequential topology optimization improve structural compliance by 90% and 58%, respectively. An industry-level example, an aerospace component, is optimized. The proposed method is used to achieve an 11% and 15% reduction of structural compliance compared to alternative FRAM designs. In addition, compliance is reduced by 43% compared to an equal-mass aluminum design.

Current research surrounding FRAM focuses on the manufacturing process and neglects opportunities to leverage design freedom provided by FRAM. Previous FRAM optimization methods only optimize fiber orientation within a 2D plane and do not establish an optimized 3D print orientation, neglecting exploration of the entire orientation design space.

The optimal material microstructures in pure material design are no longer efficient or optimal when accounting macroscopic structure performance with specific boundary conditions. Therefore, it is important to provide a novel multiscale topology optimization framework to tailor the topology of structure and the material to achieve specific applications. In comparison with porous materials, composites consisting of two or more phase materials are more attractive and advantageous from the perspective of engineering application. This paper aims to provide a novel concurrent topological design of structures and microscopic materials for thermal conductivity involving multi-material topology optimization (material distribution) at the lower scale.

In this work, the effective thermal conductivity properties of microscopic three or more phase materials are obtained via homogenization theory, which serves as a bridge of the macrostructure and the periodic material microstructures. The optimization problem, including the topological design of macrostructures and inverse homogenization of microscopic materials, are solved by bi-directional evolutionary structure optimization method.

As a result, the presented framework shows high stability during the optimization process and requires little iterations for convergence. A number of interesting and valid macrostructures and material microstructures are obtained in terms of optimal thermal conductive path, which verify the effectiveness of the proposed mutliscale topology optimization method. Numerical examples adequately consider effects of initial guesses of the representative unit cell and of the volume constraints of adopted base materials at the microscopic scale on the final design. The resultant structures at both the scales with clear and distinctive boundary between different phases, making the manufacturing straightforward.

This paper presents a novel multiscale concurrent topology optimization method for structures and the underlying multi-phase materials for thermal conductivity. The authors have carried out the concurrent multi-phase topology optimization for both 2D and 3D cases, which makes this work distinguished from existing references. In addition, some interesting and efficient multi-phase material microstructures and macrostructures have been obtained in terms of optimal thermal conductive path.

The purpose of this paper is to introduce an evolutionary heuristic method for simultaneous optimization of topology and material property distribution of functionally graded (FG) structures under a prescribed loading condition.

The proposed procedure is inspired by heuristic nature of bi-directional evolutionary structural optimization (BESO) and genetic algorithm (GA). The optimization algorithm is developed in the context of minimum compliance (maximum stiffness) design problem. The problem is modeled by means of finite element method (FEM). The element-wise material volume fractions and elements’ status (i.e. existence or nonexistence in FE model) are introduced as design variables. After FE analysis, sensitivities are obtain and filtered according to BESO. Having determined sensitivities, by means of a heuristic scheme combined by GA, topology and material property distribution for the next cycle of optimization are determined by updating design variables.

The adopted method has been tested by means of several examples previously reported in literature. The comparison showed the superiority of the proposed method against its rival in terms of relative reduction in compliance, smoother material property distribution and computational cost.

The value of the described method lies in its simple (yet efficient) nature. In contrast with its only rival in literature which more relied on mathematical approach, proposed method uses a series of logic-based heuristic ideas to drive reasonable solutions but with far less computational cost.

The purpose of this paper is to develop a multi-material topology optimization method for permanent magnet-assisted synchronous reluctance motors.

In the proposed method, the optimization procedure consists of two steps. In the first step, the entire rotor area was selected for the design region and the distribution of the core and air materials was optimized. In the second step, the design region was limited to the air region of the former solution and the distribution of magnets and cores or magnets and air was optimized.

Because of the two-step process of the proposed method, the design parameters can be reduced compared to the conventional method. As a result, this study can prevent the solution space from becoming more complex and superior solutions can be founded effectively.

Since limited case study is denoted in this paper, much more case studies, for example, three-dimensional optimization problems, are needed to be discussed.

The optimal solutions obtained by the proposed method have a smaller magnet volume and higher average torque than that of the conventional method.

In the proposed methods, optimization methodology, which consists of two-steps process, is differed from the conventional method.

In pure material design, the previous research has indicated that lots of optimization factors such as used algorithm and parameters have influence on the optimal solution. In other words, there are multiple local minima for the topological design of materials for extreme properties. Therefore, the purpose of this study is to attempt different or more concise algorithms to find much wider possible solutions to material design. As for the design of material microstructures for macro-structural performance, the previous studies test algorithms on 2D porous or composite materials only, it should be demonstrated for 3D problems to reveal numerical and computational performance of the used algorithm.

The presented paper is an attempt to use the strain energy method and the bi-directional evolutionary structural optimization (BESO) algorithm to tailor material microstructures so as to find the optimal topology with the selected objective functions. The adoption of the strain energy-based approach instead of the homogenization method significantly simplifies the numerical implementation. The BESO approach is well suited to the optimal design of porous materials, and the generated topology structures are described clearly which makes manufacturing easy.

As a result, the presented method shows high stability during the optimization process and requires little iterations for convergence. A number of interesting and valid material microstructures are obtained which verify the effectiveness of the proposed optimization algorithm. The numerical examples adequately consider effects of initial guesses of the representative unit cell (RUC) and of the volume constraints of solid materials on the final design. The presented paper also reveals that the optimized microstructure obtained from pure material design is not the optimal solution any more when considering the specific macro-structural performance. The optimal result depends on various effects such as the initial guess of RUC and the size dimension of the macrostructure itself.

This paper presents a new topology optimization method for the optimal design of 2D and 3D porous materials for extreme elastic properties and macro-structural performance. Unlike previous studies, the presented paper tests the proposed optimization algorithm for not only 2D porous material design but also 3D topology optimization to reveal numerical and computational performance of the used algorithm. In addition, some new and interesting material microstructural topologies have been obtained to provide wider possible solutions to the material design.

The purpose of this paper is to propose an improved proportional topology optimization (IPTO) algorithm for tackling the stress-constrained minimum volume optimization problem, which can meet the requirements that are to get rid of the problems of numerical derivation and sensitivity calculation involved in the process of obtaining sensitivity information and overcome the drawbacks of the original proportional topology optimization (PTO) algorithm.

The IPTO algorithm is designed by using the new target material volume update scheme and the new density variable update scheme and by introducing the improved density filter (considering the weighting function based on the Gaussian distribution) and Heaviside-type projection operator on the basis of the PTO algorithm. The effectiveness of the IPTO algorithm is demonstrated by solving the stress-constrained minimum volume optimization problems for two numerical examples and being compared with the PTO algorithm.

The results of this paper show that the uses of the proposed strategies contribute to improving the optimized results and the performance (such as the ability to obtain accurate solutions, robustness and convergence speed) of the IPTO algorithm. Compared with the PTO algorithm, the IPTO algorithm has the advantages of fast convergence speed, enhancing the ability to obtain accurate solutions and improving the optimized results.

This paper achieved the author’s intended purpose and provided a new idea for solving the stress-constrained optimization problem under the premise of avoiding obtaining sensitivity information.

There are many investigations in design methodologies, but there are also divergences and convergences as there are so many points of view. This study aims to evaluate to corroborate and deepen other researchers’ findings, dissipate divergences and provide directing to future work on the subject from a methodological and convergent perspective.

This study analyzes the previous reviews (about 15 reviews) and based on the consensus and the classifications provided by these authors, a significant sample of research is analyzed in the design for additive manufacturing (DFAM) theme (approximately 80 articles until June of 2017 and approximately 280–300 articles until February of 2019) through descriptive statistics, to corroborate and deepen the findings of other researchers.

Throughout this work, this paper found statistics indicating that the main areas studied are: multiple objective optimizations, execution of the design, general DFAM and DFAM for functional performance. Among the main conclusions: there is a lack of innovation in the products developed with the methodologies, there is a lack of exhaustivity in the methodologies, there are few efforts to include environmental aspects in the methodologies, many of the methods include economic and cost evaluation, but are not very explicit and broad (sustainability evaluation), it is necessary to consider a greater variety of functions, among other conclusions

The novelty in this study is the methodology. It is very objective, comprehensive and quantitative. The starting point is not the case studies nor the qualitative criteria, but the figures and quantities of methodologies. The main contribution of this review article is to guide future work on the subject from a methodological and convergent perspective and this article provides a broad database with articles containing information on many issues to make decisions: design methodology; optimization; processes, selection of parts and materials; cost and product management; mechanical, electrical and thermal properties; health and environmental impact, etc.

The present contribution deals with the sensitivity analysis and optimization of structures for path‐dependent structural response. Geometrically as well as materially non‐linear behavior with hardening and softening is taken into account. Prandtl‐Reuss‐plasticity is adopted so that not only the state variables but also their sensitivities are path‐dependent. Because of this the variational direct approach is preferred for the sensitivity analysis. For accuracy reasons the sensitivity analysis has to be consistent with the analysis method evaluating the structural response. The proposed sensitivity analysis as well as its application in structural optimization is demonstrated by several examples.

This paper aims to provide a comprehensive review of the state-of–the-art design methods for additive manufacturing (AM) technologies to improve functional performance.

In this survey, design methods for AM to improve functional performance are divided into two main groups. They are design methods for a specific objective and general design methods. Design methods in the first group primarily focus on the improvement of functional performance, while the second group also takes other important factors such as manufacturability and cost into consideration with a more general framework. Design methods in each groups are carefully reviewed with discussion and comparison.

The advantages and disadvantages of different design methods for AM are discussed in this paper. Some general issues of existing methods are summarized below: most existing design methods only focus on a single design scale with a single function; few product-level design methods are available for both products’ functionality and assembly; and some existing design methods are hard to implement for the lack of suitable computer-aided design software.

This study is a useful source for designers to select an appropriate design method to take full advantage of AM.

In this survey, a novel classification method is used to categorize existing design methods for AM. Based on this classification method, a comprehensive review is provided in this paper as an informative source for designers and researchers working in this field.

The purpose of this paper is to propose an effective and efficient numerical method that can consider natural frequency in multi-material topology optimization (MMTO) and which is scalable for complex three-dimensional (3D) problems.

The optimization algorithm is developed by combining custom FORTRAN code for MMTO with the open-source software Mystran, which is used as a finite element analysis (FEA) solver. The proposed algorithm allows the designer to shift the fundamental frequency of the design beyond a defined frequency spectrum from the initial designing phase. The methodology is formulated in a smooth and differentiable manner, with the sensitivity expressions, required by gradient-based optimization solvers, presented.

Natural frequency constraint has been successfully implemented into MMTO. The use of open-source software Mystran as an FEA solver in the algorithm provides ability to solve complex problems. Mystran offers powerful built-in functions for eigenvalue extraction using methods like Givens, modified Givens, inverse power and the Lanczos method, which provide the ability to solve complex models. The algorithm is successfully able to solve both two- and three-material MMTO jobs for two-dimensional and 3D geometries.

Natural frequency constraint consideration into topology optimization is very challenging due to three common issues: localized eigenmodes, mode switching and high computational cost. The proposed algorithm addresses these inherent issues, implements natural frequency constraint to MMTO and solves for complex models, which is hardly possible using conventional methods.