Topology Optimization of Heat Conduction Structures for Hybrid Additive and Subtractive Manufacturing

To achieve structure manufacturability and performance optimization in hybrid additive-subtractive manufacturing, this research proposed a topology optimization method for hybrid manufacturing with the “additive first, subtractive later” sequence. Based on the heat conduction structural topology optimization, this method introduced a density function-based additive manufacturing (AM) filter to satisfy the self-support constraint of overhanging surfaces during AM. In addition, we introduced a convection-diffusion equation-based multi-axis subtractive manufacturing (SM) filter to satisfy the tool accessibility constraint during multi-axis SM. The proposed algorithm reduced the amount of support material required in additive manufacturing and shortened the post-processing cost. Meanwhile, by integrating the multi-axis subtractive manufacturing process into the optimization, it effectively improved the surface quality and shape accuracy of structures. Finally, 2D and 3D heat conduction structure case studies were conducted to verify the manufacturability of the proposed topology optimization method for hybrid additive-subtractive manufacturing.