Interlinking multiphysics and multiscale simulations with topology optimization in additive manufacturing processes

Even though process simulation for 3D printing have progressed substantially over the past decade and across multiple length-scale, the major issue is about how to link these simulations and then perhaps to combine these interlinked holistic models with topology optimization techniques for getting an improved design. Here the solution is the use of multi-scaling laws which are; homogenization, material multi-scaling and finally, process multi-scaling. The first two multi-scaling techniques allow for extracting macroscopic properties of an entire part based on the data generated by process simulations at lower dimensions, namely micro- and deposition-scale models while process multi-scaling methods enable fast and robust computation of a real-size sample and such models can be improved by involving the material multi-scaling calculations into them. Finally, this holistic model can be incorporated into the topology optimization calculations for a far better design of a part with ultimate no sign of a process-induced defect, under the flag of physics-aware topology optimization.