DESIGN FOR ADDITIVE MANUFACTURING OF TOPOLOGICALLY OPTIMIZED AIR MANIFOLD

Topology optimization is increasingly utilized in mechanical component design to achieve lightweight, cost-effective, and functional designs, facilitated by advanced design software and additive manufacturing technologies. This study presents a workflow for redesigning a low-pressure air manifold using cutting-edge design processes and Selective Laser Sintering (SLS) 3D printing with polyamide 12 (PA12). Through iterative finite element analyses (FEA), unnecessary material regions were removed and novel surface-architected materials were applied to critical areas to enhance its structural integrity. The final design, evaluated computationally under realistic conditions, demonstrated a weight reduction of up to 76% compared to the initial design, with production costs below €5 per item. The presented workflow provides a generic pipeline for the redesign and topology optimization processes of a manifold, which can be applicable to other similar 3D-printed mechanical parts derived from industries constructed either from metal or from polymer, such as hydraulic manifolds, nozzles, connectors, etc.