Topological Optimization In 3D Printing Design

Roslan, Fauzei (2017) Topological Optimization In 3D Printing Design. Project Report. UTeM, Melaka, Malaysia. (Submitted)

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Abstract

In the industry sector, the demand for material even more so raw material has risen quite a lot in this coming years. The purpose of this thesis was to conduct the process of topology optimization on an object, then test it whether or it is viable to be printed using 3D printer. Afterward evaluate the data from the experimental and the theoretical data. The topological optimization process is a revolutionary process in which it reduce the use of material but still able to maintain the product mechanical characteristic and its feature. In this thesis, the part chosen was a brake pedal, it is believe that there is still room for improvement to be done. The brake pedal was then constructed into a 3D model using CAD then it was imported into the Optimization software. After the topology optimization process was completed, the final design and a number of sets of data was obtain. From the final design, it was reconstructed back using CAD software to look similar to the final optimization design. Afterward the 3D model of the final design was then printed using CubePro 3D printer. The finish product of the 3D printer was then compare with 3D model. The max value of data obtained from the analysis for the deflection value drop 86.84%, the von mises value increased about 40.06%, the pressure drastically about 90% and for the max shear stress increase 33.3%. For its exterior data obtained from using CATIA CAD is was determined that the weight was reduce up to 33.33%, the volume also reduce 15% but the area stayed the same. The data comparison between the 3D model CAD and the actual printed part is undesirable the overall aesthetic appeal was only satisfactory. The data obtained was as expected even with the CubePro because the ABS 3D printer are well known for their weakness. The aim to determine the viability of printing the topology optimize part was achieve and the result it just on the level satisfactory.

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