Topology optimization for additive manufacturing of carbon fiber-reinforced composite structures with failure criteria

Abstract Additive manufacturing (AM) has opened new avenues for the design and fabrication of carbon fiber-reinforced polymer (CFRP) structures, offering unprecedented flexibility in tailoring material distribution and structural layouts. This study introduces a topology optimization framework that integrates the Tsai–Wu failure criterion to enhance structural strength. The framework utilizes the discrete material and thickness optimization (DMTO) method, enabling simultaneous optimization of material distribution and fiber orientation, with the process driven by the method of moving asymptotes (MMA) optimization algorithm. To ensure computational efficiency, failure criteria are incorporated through a p -norm aggregation approach. Numerical case studies demonstrate that the proposed approach can reduce the maximum failure indicator by more than 59.6% and increase the load-bearing capacity by up to 32.5% compared with compliance-only designs. Overall, the study highlights the importance of incorporating failure criteria into topology optimization for the reliable design and additive manufacturing of high-performance CFRP structures.