Design for tape-reinforced additive manufacturing using geometric projection topology optimization

The pursuit of high-performance structures requires innovative manufacturing approaches that balance multiple competing factors. This work focuses on one such novel approach, named Advanced Tape Laying Additive Manufacturing (ATLAM), that integrates the characteristics of automated tape laying and additive manufacturing. ATLAM supported by a dedicated complementary design tool can provide a unique ability to balances mechanical performance, manufacturing flexibility, and eco-efficiency. To exploit the full potential of ATLAM in manufacturing lightweight sustainable structures, we aim to develop, verify and experimentally validate a computational design tool rooted in topology optimization. We use geometric projection topology optimization framework, and tailor it to accommodate ATLAM’s unique features and constraints. We customize the geometric primitive, the projection & material interpolation schemes and design/manufacturing constraints. Then, based on numerical investigation, we showcase excellent effectiveness and robustness of the proposed approach in optimizing geometry and reinforcement placements and designing stiffer yet manufacturable structures. An environmental impact constraint is incorporated to enable a design choice on sustainability. Finally, we experimentally validate our proposed approach, paving the way for reliable use in real-world applications.