Research: Optimising Topology for Lightweight Metal Structures in Additive Manufacturin...

Research question: How can topology optimisation techniques improve the mechanical performance and weight reduction of metal structures fabricated by additive manufacturing?

Additive manufacturing (AM) enables the fabrication of complex metal geometries that are difficult or impossible to achieve with traditional manufacturing methods. The ability to create lightweight structures with tailored mechanical properties is particularly valuable in aerospace, automotive, and biomedical engineering.

Despite significant advances in AM, there remain challenges in optimising structural topology for weight reduction while maintaining mechanical integrity. Existing literature often focuses on theoretical models or simulation studies, with limited experimental validation of optimised designs produced via AM. This gap motivates the investigation of practical topology optimisation techniques validated by physical testing.

This thesis will combine computational topology optimisation (using methods such as finite element analysis and gradient-based algorithms) with fabrication via selective laser melting (SLM) and mechanical testing of optimised metal structures. The study will benchmark different optimisation approaches, evaluate manufacturability constraints, and analyse the mechanical performance of fabricated samples.

The project’s findings will inform best practices for designing lightweight, high-performance metal structures for AM, contributing to more efficient and sustainable engineering solutions. This research is relevant for industries seeking to leverage AM for advanced structural applications.