Design analysis and 3D printing of a medium-sized metal component: a case study on topological optimization

Abstract

Additive Manufacturing technologies have revolutionized the manufacturing industry by enabling the fabrication of complex geometries with unprecedented design freedom. This Bachelor’s Degree Thesis explores how topological optimization can be used in metal pieces as a mean to enhance their structural performance such that, maintaining the piece required properties, diminishes its material used, hence reducing weight and price. This technique holds a tremendous potential to reduce material consumption when designing components. By employing software and simulation tools such as SolidWorks and Ultimaker Cura, as well as hardware as the Prusa i3 MK3S+ 3D printer, the research seeks to identify the most efficient material arrangement of the pieces. It is of utmost importance to maintain the mechanical properties while considering the constraints of additive manufacturing. The final scope of this research is supporting 2 projects of different companies in which both a piece of equipment needs to be optimized. On the one hand, a part of an injection blow mold for the manufacture of a container for the pharmaceutical industry is studied. On the other hand, a gear belonging to Enpa, a gear manufacturing company. The thesis encompasses a thorough review of existing literature on additive manufacturing in this sector. A case study of tensile test specimens is carried out to analyze the practical results of a piece being optimized topologically. Through this experimental validation, the thesis demonstrates the potential benefits of implementing topological optimization. In conclusion, the findings suggest that the successful simulations carried out with both metal components, gear and pharmaceutical, could be extrapolated into practice which would imply a significant reduction in weight and material usage.