Bibliography
Journal Article
Modular-topology optimization for additive manufacturing of reusable mechanisms
, , , ,
: Computers and Structures vol.307,
: GX19-26143X, GA ČR, L100752301, GA AV ČR
: Modular-topology optimization, Reusability, Free-material optimization, Additive manufacturing, Modularity, Compliant mechanism
: 10.1016/j.compstruc.2024.107630
: https://library.utia.cas.cz/separaty/2025/MTR/tyburec-0603316.pdf
(eng): Modular designs have gained popularity because they can generally address manufacturing efficiency, reusability, and sustainability concerns. Here, we contribute to the growing field by proposing a fully automatic design method for modules utilized in several products. Our manufacturing-aware procedure is composed of three consecutive steps: (i) free-material optimization for obtaining the optimal spatially distributed elasticity tensors, (ii) hierarchical clustering of the stiffness tensors directly into a given number of modules while allowing for their flipping, and (iii) single-scale topology optimization with manufacturing aspects to design the final topology of mechanically compatible modules. These aspects include connectivity constraints to ensure the integrity of all modules and the three-field projection to account for manufacturing inaccuracies. We illustrate the entire procedure with the design and fabrication of eight different reusable modules assembled into well-functioning modular inverter and gripper mechanisms. These mechanisms were 3D printed and subjected to mechanical testing using an in-house testing machine and digital image correlation. The experimental results show excellent agreement between the predicted and observed behavior and highlight the potential of the method for scalable additive manufacturing.
: JI
: 20101