Multi-Objective Build Orientation and Topology Optimization for Cost and Time Minimization in Fiber Reinforced Additive Manufacturing

Fiber Reinforced Additive Manufacturing (FRAM) combines the geometric freedom of additive manufacturing with the high stiffness-to-weight ratio of composite materials, enabling the production of lightweight, high-performance components. The anisotropic nature of fiber-reinforced composites makes their mechanical performance highly dependent on fiber orientation relative to applied loads. This directional behavior can be exploited through optimization of both component geometry, via topology optimization (TO), and build orientation, via build orientation optimization (BOO), to maximize structural efficiency. Historically, FRAM research has focused primarily on structural objectives such as compliance minimization, often neglecting non-structural considerations like support structure minimization. Support structures, which are temporary features required for fabricating overhangs, can substantially increase print time, material consumption, and overall cost. To address this gap, this research presents a novel multi-objective optimization framework that simultaneously minimizes compliance and support structures, integrating Design for Additive Manufacturing (DfAM) principles with structural optimization. The integrated TO+BOO methodology is applied to an Aircraft Fuselage Bracket, achieving an 80% reduction in compliance compared to an equivalent mass Aluminum bracket. Relative to a fixed-orientation FRAM baseline, the method delivered substantial manufacturing benefits, including a 68.8% reduction in cost and a 61.2% decrease in print time, while incurring only a 7.2% increase in compliance. This work establishes a practical framework for FRAM that bridges performance-driven design and manufacturing efficiency, demonstrating that the integration of DfAM principles can produce cost-effective, high-performance components suitable for real-world applications.

Department dc:contributor.department

Mechanical and Materials Engineering

Year dc:date.issued

2025

Author dc:creator

• Wotten, Erik Davis

Advisor dc:contributor.supervisor

• Kim, Il Yong

• Fiber Reinforced Additive Manufacturing
• Topology Optimization
• Build Orientation Optimization
• Support Structure
• Cost and Time

Statement dc:rights

• Attribution-NonCommercial-NoDerivatives 4.0 International

Licence dc:rights.uri

• http://creativecommons.org/licenses/by-nc-nd/4.0/

Handle dc:identifier.uri

https://hdl.handle.net/1974/35299

OAI identifier oai:identifier

oai:queensu.scholaris.ca:1974/35299