Minimum Length and Overhang Constraints for both Level Set and Density Approaches via Perimeter Minimization
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The transport industry is confronted with an important challenge in the pursuit of lightweight structures to reduce fuel consumption and environmental impact. Topology optimization techniques have demonstrated their effectiveness not only in weight reduction but also in the exploration of new innovative designs, thereby extending their utility beyond mere structural efficiency. These techniques play a pivotal role in minimizing design time and reducing costs. However, these methods often yield complex designs that are feasible only through additive manufacturing. To address this challenge, numerical optimization must be integrated with 3D printing constraints to ensure manufacturability. These constraints include considerations such as minimal length scale and overhang constraints. In this context, our paper explores the feasibility of optimal design within the additive manufacturing process. A novel concept of anisotropic perimeter is introduced to penalize overhang constraints in the 3D printing direction, as well as the small length scales. Various case studies are defined to evaluate their feasibility. Our results indicate that the inclusion of overhang constraints leads to the removal of local bars with small length scales. Additionally, a prevalent vertical tendency orientation of bars is observed, demonstrating the effectiveness of our approach in addressing overhang challenges in the context of additive manufacturing.