Topology Optimization and Additive Manufacturing of Lightweight Cantilever Beams: Design, Fabrication, and Cost Analysis

Abstract This paper discusses the design and optimization of a cantilever beam through topology optimization combined with extrusion-based additive manufacturing (AM). The aim was to achieve a considerable weight reduction while preserving adequate load-bearing capacity under a 0.5 kg load. Topology optimization was conducted in Altair Inspire with a mass objective of 15–25% of the initial volume, subsequently followed by geometric refinement utilizing PolyNURBS to guarantee manufacturability. The optimized models were produced with Fused Filament Fabrication (FFF) on a FlashForge Creator Pro, employing PLA as the feedstock material. Process parameters comprising a 0.2 mm layer height, 20–33% infill density, and customized support structures were chosen to optimize mechanical strength, precision, and material efficiency. Experimental validation demonstrated that the improved beams withstood loads of up to 1 kg without deformation, while von Mises stresses were far below the yield strength of PLA. Despite the optimized design demonstrating reduced safety factors relative to the baseline, structural integrity was maintained. A cost analysis revealed that AM decreased costs by 77% relative to CNC machining, while facilitating the creation of intricate geometries unattainable by traditional methods. The results highlight the possibility of integrating topology optimization with AM to produce lightweight, economical, and structurally efficient components, offering a feasible approach for engineering applications necessitating strength-to-weight optimization.