Optimal toolpath design of additive manufactured composite cylindrical structures

Fernandez, Felipe; Lewicki, James P.; Tortorelli, Daniel A.

doi:10.1016/j.cma.2021.113673

Optimal toolpath design of additive manufactured composite cylindrical structures

Journal Article · Thu Jan 21 23:00:00 EST 2021 · Computer Methods in Applied Mechanics and Engineering

DOI:https://doi.org/10.1016/j.cma.2021.113673· OSTI ID:1763942

^[1]; Lewicki, James P. ^[1]; Tortorelli, Daniel A. ^[2]

Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States)
Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States); Univ. of Illinois at Urbana-Champaign, IL (United States)

Structural design optimization for additive manufacturing is primarily focused on planar layer-by-layer processes and design of composite cylindrical structures does not often accommodate manufacturing constraints. In this study, we propose to optimize the toolpath trajectory of additively manufactured composite cylinders comprised of multiple thin cylindrical annuli. Additionally, our printing process is based on direct ink writing in which short carbon fibers in a thermoset resin are extruded through a moving nozzle to build up a structure. Since the fibers are primarily aligned in the flow direction of the extrudate, the printing trajectory influences the material properties of the composite structure. To accommodate this, we define the toolpaths as contours of parameterized level-set functions. This parameterization allows us to optimize the material properties and impose manufacturing constraints such as no-overlap, no-sag, minimum radius of curvature, and continuity of the toolpaths. Several examples illustrate the optimization procedure.

View Accepted Manuscript (DOE)

Research Organization:: Lawrence Livermore National Laboratory (LLNL), Livermore, CA (United States)

Sponsoring Organization:: USDOE National Nuclear Security Administration (NNSA)

Grant/Contract Number:: AC52-07NA27344

OSTI ID:: 1763942

Alternate ID(s):: OSTI ID: 1809480

Report Number(s):: LLNL-JRNL--815097; 1023397

Journal Information:: Computer Methods in Applied Mechanics and Engineering, Journal Name: Computer Methods in Applied Mechanics and Engineering Journal Issue: no. 0045-7825 Vol. 376; ISSN 0045-7825

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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