From topology optimisation to metal fused filament fabrication: Geometric export for optimised models

This study presents a workflow for producing a topology‐optimised part using metal fused filament fabrication technology. Using Altair Inspire, the mass was reduced by over 50 % while maintaining a minimum safety factor of four. Four export strategies were evaluated: automatic mesh (fast and non‐editable); automatic model fitting (fast and editable); manual model wrapping (slow, editable and producing the highest surface quality) and computer‐aided design‐based reverse engineering (slow and for simple geometries). Models based on using non‐uniform rational B‐spline faces and the computer‐aided design‐based reverse engineering approach produced a file with the standard for the exchange of product model data format that could be used directly in a computer‐aided design environment. The wrapped model was then additively manufactured from stainless steel using a fused deposition modelling printer. Catalytic debinding and sintering were then performed to obtain the final metal part.