Optimizing Additive Manufacturable Structures with Computer Vision to Enhance Material Efficiency and Structural Stability

This study introduces an innovative technique that merges computer vision with topology optimization to advance additive manufacturing. Employing advanced photogrammetry software, we obtain high-resolution images of the design domain, which are then used to develop accurate 3D models through meticulous scanning procedures. These models are transformed into an STL file format and remeshed using an adaptive algorithm within COMSOL 5.3 Multiphysics, facilitated by a custom MATLAB 2023 application. This integration achieves the optimal mesh resolution and precision in analytical assessments. We applied this technique to the design of a concrete pillar for 3D printing, targeting a 75% reduction in volume to improve the material efficiency and structural stability—critical factors for extraterrestrial applications. The design, captured with a 360-degree camera array, guided the MATLAB-based topology optimization process. By combining MATLAB’s optimization algorithms with COMSOL’s meshing and finite element analysis tools, we investigated various material-efficient configurations. The findings reveal a substantial volume reduction, especially in the central region of the design, effectively optimizing material utilization while preserving structural integrity. The optimization algorithm exhibited a swift and stable convergence, reaching near-optimal solutions within approximately 20 iterations.