Topology optimization of additive manufactured CFRP structures with anisotropy properties to minimize frequency response

Purpose This study aims to present a novel topology optimization method for effectively minimizing the frequency response over a given frequency interval considering anisotropic features and fiber angles simultaneously. Design/methodology/approach The variable thickness sheet (VTS) method is used to obtain a free material distribution under the specified volume constraint. The anisotropic equivalent stiffness matrix based on the material fiber angles is considered in the orthotropic material properties model, which ensures a sufficiently large design space to minimize the frequency response. To lessen the computational burden, the quasi-static Ritz vector (QSRV) method is integrated to approximate the structural response. Findings Compared to considering only one element, the optimization process simultaneously considers the spatially-varying fiber angles and the material distribution, allowing for a broader design space to minimize the frequency response of additive manufacturing (AM) structures. The orthotropic properties play an important role in determining optimal material distribution of the structure. Moreover, the QSRV method makes the frequency response analysis more efficient. Originality/value The anisotropic stiffness and spatially-varying angles of the fiber materials induced by the layer-by-layer printing process of carbon fiber reinforced plastics (CFRP) are simultaneously considered to further minimize the frequency response of AM structures, which improves the performance of AM-CFRP structures.