Weight Reduction of Fused Deposition Modeling Manufactured PLA Structures through Topology Optimization
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Keywords:
PLA, Topology Optimization, Weight ReductionAbstract
The interaction between additive manufacturing (AM) and Topology Optimization (TO) offers
a powerful example to create lightweight, high performance structural components. This study
investigates this combined approach by designing and analyzing a bracket made of Polylactic Acid (PLA)
using the fused deposition modeling (FDM) manner. Finite Element Analysis (FEA) was conducted using
ANSYS software to perform a static structural analysis on an initial bracket model. Subsequently,
topology optimization was employed to minimize compliance (maximize stiffness) under two distinct
volume constraints, targeting final volumes of 70% and 50% of the original design space. The initial
analysis revealed a notable dissociation between the locations of maximum total deformation (2.130 mm
at the component’s tip) and maximum equivalent stress (153.48 MPa at the bracket’s base and fixture
points). The optimization process successfully yielded two distinct lightweight geometries that effectively
follow the identified primary load paths, validating the TO strategy. The findings demonstrate that
combining FDM and TO is a highly effective method for achieving significant weight reduction. The
comparison between the 70% and 50% volume models illustrates a critical balance between mass savings
and increased stress concentration. This study validates the simulation-driven design process as a robust
tool for developing structurally efficient components tailored for applications where weight is a critical
parameter.
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