Topology Optimization of Fe-SMA Clamp Structures for Additive Manufacturing and the Influence of Design Parameters

Shape memory alloys (SMAs) are attractive functional structural materials due to their ability to recover their original shape after deformation. Among them, Fe-based SMAs (Fe-SMAs) are promising for structural applications because of their low cost, high strength, and compatibility with conventional processing. With the progress of metal additive manufacturing (AM), it has become possible to fabricate Fe-SMA components with complex geometries, creating opportunities to combine SMA functionality with topology optimization.</br>This study investigates the effects of key topology optimization parameters on the structural response of Fe-SMA clamp components. A finite element analysis (FEA) framework with linear elastic material behavior was established to examine the influence of mesh size, material volume fraction, lattice size, and optimization method (Density-based, Level-set, Mixed, Shape) on stress distribution and structural performance.</br>The results show that mesh refinement improved accuracy but increased computational cost, identifying 0.375 mm as the optimal mesh size. Reducing the volume fraction achieved up to 40% material savings while maintaining structural integrity, though local stress concentrations increased. Lattice size affected stress oscillation and efficiency, while different optimization methods revealed trade-offs between volume reduction and stress distribution.