Anisotropic Effects on Topology Optimization for Additive Manufacturing in Aerospace Applications

This study investigates the effects of anisotropy on topology optimization in additive manufacturing, with a focus on aerospace applications. Topology optimization, a powerful design method for lightweight structures, is increasingly relevant in aerospace due to the adoption of additive manufacturing techniques. However, the anisotropic nature of materials used in these processes is often overlooked. This research compares isotropic and anisotropic analyses using TiAl4V and Epoxy Carbon UD Prepreg materials, examining stress distributions and optimization times. A cubic sample (40 mm) was subjected to various loading conditions, with a 10% mass retention constraint. Results demonstrate significant differences in stress levels and solution times between isotropic and anisotropic optimizations. For TiAl4V, the anisotropic analysis revealed notable variations in stress distribution and optimization times compared to isotropic assumptions. The composite material analysis further emphasized the importance of considering directional properties in optimization. Additionally, comparing aluminum and titanium components highlighted potential weight savings in certain applications. This study underscores the importance of incorporating anisotropic material properties in topology optimization for additive manufacturing, particularly in aerospace applications where weight reduction and structural integrity are critical. The findings suggest that anisotropic optimization could lead to more efficient designs and reduced computational times in specific loading scenarios.