Novel robust formulation for manufacturing tolerant topology optimization

Accurate control of manufacturing tolerance has long been a challenge in the field of topology optimization. Within density-based frameworks, existing analytical methods tend to only provide approximated solutions, whilst numerical methods heavily rely on trial-and-error to achieve desirable manufacturing tolerance. At the same time, these strategies assume identical topology across the upper and lower tolerance bounds, which can lead to inaccurate prediction of the fabricated outcome. This paper aims to address these problems through a novel robust topology optimization scheme, termed explicit-thickness-controlled-robust, which utilizes p-norm functions as filters to produce eroded and dilated designs from a base physical design field. The exact thicknesses are prescribed by the radii of the filters, which mimic the lower and upper bounds of manufacturing tolerance. This method is notable for its ease of implementation and meeting precise thickness requirements. The formulation is integrated with the floating projection topology optimization framework, allowing the realization of smooth topologies. 2D and 3D compliance minimization case studies demonstrate the technique’s versatility and compatibility. • A new robust topology optimization algorithm is proposed. • Tackles the challenge of accurate manufacturing tolerance in topology optimization. • Provides intuitive, precise control over manufacturing tolerances. • Produces smooth designs ready to manufacture with no additional processing.