Multi-scale Topology Optimisation with Overheating Control for Laser Powder Bed Fusion

Key Points

• The aim is to present a multi-scale method for topology optimisation (TO) that effectively manages overheating using homogenised properties.
• Developed a novel multi-scale approach for TO focused on BCC lattice cell homogenisation.
• Used elasticity and thermal conductivity for material interpolation based on density.
• Applied Heaviside function to impose manufacturing limits on relative density.
• Experimentally determined fabrication limits for Ti6Al4V alloy and BCC lattice cell size.
• Achieved effective interpretation of intermediate densities using varying lattice structures.
• Demonstrated new overheating control mechanisms in the topology optimisation process.
• Validated methods through experimental assessments of powder accessibility and feature size.