A hollowing algorithm for a parametric optimisation method of structural components

The growing use of additive manufacturing to obtain finished components has led scientific research to increase the studies on topological optimization methods. Thanks to this it is possible to reduce the weight of the components, guaranteeing the desired mechanical properties. In this paper, a new algorithm of parametric optimization is used. Using the Finite Element Analysis, the algorithm uses a grid of prefixed points on the optimizable piece to hollow it. The stresses coming from the Finite Element Analysis are used to parametrize the hollowing process varying the size of the hole. The software used in this work are Grasshopper (a Rhinoceros plug-in) to implement the algorithm and Ansys Workbench to carry out the Finite Element Analysis. The used algorithm directly modifies the original CAD with the optimised one. This is the greatest potential of the method. Furthermore, this method can be used with both additive and subtractive manufacturing. The case study is a plate for structural application. It has been designed and tested with the Finite Element Analysis. After the optimization with the proposed algorithm, a new Finite Element Analysis has been carried out on the optimised plate to compare the two behaviours. Both the plates have been printed using a Fused Deposition Modeling technique also to evaluate the differences between the printing time. The optimised plate can still resist to the imposed loads without achieving the yield stress.