Systematic integration of topology optimization techniques in design for additive manufacturing methodologies applied to automotive settings

Additive Manufacturing is having a great trend since its implementation possible benefits have been widely discussed and efforts in technology improvements are having impact on process reliability and industrial application. The aims of this work are to analyze the current and forthcoming scenario of methods for the specific development of parts to be produced by metal AM including topology optimization as a basic design step and to demonstrate that systematical design approaches can be introduced in order to better exploit potentials offered by AM implementation. The general framework composed by the main tasks is introduced and discussed. Key factors such as advance in different design solutions exploration, product-related and process-related design constraint implementation in the design phase and method effectiveness in product development lead time minimization are presented. Linear and iterative workflows are described, considering features, decision making points, pros and cons, possible variants and research hints. A strong connection between methods and actual means is highlighted and workflow implementation using standard and integrated commercial tools is considered. Such methods are related to several automotive case studies presented in order to demonstrate their applicability and to show actual results and possible further development..