Customization of Automotive Structural Components using Additive Manufacturing and Topology Optimization

This paper presents a framework for the design of automotive components using topology optimization and additive manufacturing (AM). The long production times, post processing, and surface quality of AM processes deters companies from deploying it as a true manufacturing solution, often relegating it to the prototyping stage. Many improvements will be necessary to overcome these deficiencies, however the newest developments in design for additive manufacturing show promise. The use of topology optimization with an overhang and build time constraint can help maximize the advantages of AM, while reducing the issues of wasteful support material and lengthy print times. A case study is presented that explores a practical example of a high-performance vehicle upright and its design using topology optimization.