Optimization-based Design for Manufacturing
J. Robbins, M.A. Aguilo, R. Alberdi, B. Clark, B. Jared, S. Jensen, K. Johnson, and R. Viertel
Abstract
This work comprehensively documents the development and integration of advanced optimization algorithms within the Plato software to enable optimization-based design for additive manufacturing. It details the implementation of forward and adjoint finite element solvers for simulating elastoplastic and thermo-elastoplastic physics, which are used within a design optimization framework to predict the residual stress tensor at every material point. Design criteria were formulated and implemented to minimize residual stress in additively manufactured components, enhancing structural performance and reliability. Additionally, this work presents topology and shape optimization algorithms tailored for additive manufacturing, supported by numerical examples demonstrating their application. The documented methodologies and results provide valuable insights into leveraging computational design optimization for improving additive manufacturing processes.