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Dr. Yun-Fei Fu
School of Engineering, Deakin University, Waurn Ponds, Australia

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Research Keywords & Expertise

0 Additive Manufacturing
0 Structural Optimization
0 Design for Additive Manufacturing
0 topology optimization
0 computational methods

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Journal article
Published: 29 December 2020 in Applied Sciences
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The smooth design of self-supporting topologies has attracted great attention in the design for additive manufacturing (DfAM) field as it cannot only enhance the manufacturability of optimized designs but can obtain light-weight designs that satisfy specific performance requirements. This paper integrates Langelaar’s AM filter into the Smooth-Edged Material Distribution for Optimizing Topology (SEMDOT) algorithm—a new element-based topology optimization method capable of forming smooth boundaries—to obtain print-ready designs without introducing post-processing methods for smoothing boundaries before fabrication and adding extra support structures during fabrication. The effects of different build orientations and critical overhang angles on self-supporting topologies are demonstrated by solving several compliance minimization (stiffness maximization) problems. In addition, a typical compliant mechanism design problem—the force inverter design—is solved to further demonstrate the effectiveness of the combination between SEMDOT and Langelaar’s AM filter.

ACS Style

Yun-Fei Fu; Kazem Ghabraie; Bernard Rolfe; Yanan Wang; Louis N. S. Chiu. Smooth Design of 3D Self-Supporting Topologies Using Additive Manufacturing Filter and SEMDOT. Applied Sciences 2020, 11, 238 .

AMA Style

Yun-Fei Fu, Kazem Ghabraie, Bernard Rolfe, Yanan Wang, Louis N. S. Chiu. Smooth Design of 3D Self-Supporting Topologies Using Additive Manufacturing Filter and SEMDOT. Applied Sciences. 2020; 11 (1):238.

Chicago/Turabian Style

Yun-Fei Fu; Kazem Ghabraie; Bernard Rolfe; Yanan Wang; Louis N. S. Chiu. 2020. "Smooth Design of 3D Self-Supporting Topologies Using Additive Manufacturing Filter and SEMDOT." Applied Sciences 11, no. 1: 238.

Research article
Published: 04 October 2020 in Australian Journal of Mechanical Engineering
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Additive manufacturing (AM) technology has been developed for more than thirty years and has become a mainstream manufacturing process. Sustainability is becoming increasingly significant for human’s health. In recent years, studies have been carried out to make AM a sustainable manufacturing technique. In this paper, research in improving manufacturing sustainability of material extrusion AM is reviewed. Studies with the aim of saving material, production time and energy in material extrusion AM processes are discussed. Future potential research directions are also identified for making AM more sustainable in the future.

ACS Style

Jingchao Jiang; Yun-Fei Fu. A short survey of sustainable material extrusion additive manufacturing. Australian Journal of Mechanical Engineering 2020, 1 -10.

AMA Style

Jingchao Jiang, Yun-Fei Fu. A short survey of sustainable material extrusion additive manufacturing. Australian Journal of Mechanical Engineering. 2020; ():1-10.

Chicago/Turabian Style

Jingchao Jiang; Yun-Fei Fu. 2020. "A short survey of sustainable material extrusion additive manufacturing." Australian Journal of Mechanical Engineering , no. : 1-10.

Articles
Published: 24 July 2019 in Virtual and Physical Prototyping
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Incorporating additive manufacturing (AM) constraints in topology optimisation can lead to performance optimality while ensuring manufacturability of designs. Numerical techniques have been previously proposed to obtain support-free designs in AM, however, few works have verified the manufacturability of their solutions. Physical verification of manufacturability becomes more critical recalling that the conventional density-based topology optimisation methods will inevitably require post-processing to smooth the boundaries before sending the results to a 3D printer. This paper presents the smooth design of self-supporting topologies using the combination of a new Solid Isotropic Microstructure with Penalisation method (SIMP) developed based on elemental volume fractions and an existing AM filter. Manufacturability of selected simulation results are verified with Fused Deposition Modeling (FDM) technology. It is illustrated that the proposed method is able to generate convergent self-supporting topologies which are printable using FDM.

ACS Style

Yun-Fei Fu; Bernard Rolfe; Louis N. S. Chiu; Yanan Wang; Xiaodong Huang; Kazem Ghabraie. Design and experimental validation of self-supporting topologies for additive manufacturing. Virtual and Physical Prototyping 2019, 14, 382 -394.

AMA Style

Yun-Fei Fu, Bernard Rolfe, Louis N. S. Chiu, Yanan Wang, Xiaodong Huang, Kazem Ghabraie. Design and experimental validation of self-supporting topologies for additive manufacturing. Virtual and Physical Prototyping. 2019; 14 (4):382-394.

Chicago/Turabian Style

Yun-Fei Fu; Bernard Rolfe; Louis N. S. Chiu; Yanan Wang; Xiaodong Huang; Kazem Ghabraie. 2019. "Design and experimental validation of self-supporting topologies for additive manufacturing." Virtual and Physical Prototyping 14, no. 4: 382-394.

Articles
Published: 23 July 2019 in Virtual and Physical Prototyping
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This paper aims to explore the effects of optimisation parameters (the filter radius, mesh size, and target volume fraction) on the compliance and manufacturability of smooth self-supporting topologies for additive manufacturing (AM); and conduct manufacturability experiments of selected simulation results with the Selective Laser Melting (SLM) technology. In this study, smooth self-supporting topologies are obtained with a combined method of the Solid Isotropic Microstructure with Penalization method (SIMP) with the smooth boundary representation and Langelaar's AM filter. Numerical examples illustrate that a higher filter radius can lead to simpler smooth self-supporting topologies, but curved top corners that violate the critical overhang angle of 45° are inevitably generated. Additionally, the mesh size is found to be not as an important factor as the filter radius in affecting the manufacturability and performance. As a result of the self-supporting constraint, a small volume fraction can easily result in structural discontinuity. The experimental results demonstrate that the self-supporting topologies obtained are all printable in SLM.

ACS Style

Yun-Fei Fu; Bernard Rolfe; Louis N. S. Chiu; Yanan Wang; Xiaodong Huang; Kazem Ghabraie. Parametric studies and manufacturability experiments on smooth self-supporting topologies. Virtual and Physical Prototyping 2019, 15, 22 -34.

AMA Style

Yun-Fei Fu, Bernard Rolfe, Louis N. S. Chiu, Yanan Wang, Xiaodong Huang, Kazem Ghabraie. Parametric studies and manufacturability experiments on smooth self-supporting topologies. Virtual and Physical Prototyping. 2019; 15 (1):22-34.

Chicago/Turabian Style

Yun-Fei Fu; Bernard Rolfe; Louis N. S. Chiu; Yanan Wang; Xiaodong Huang; Kazem Ghabraie. 2019. "Parametric studies and manufacturability experiments on smooth self-supporting topologies." Virtual and Physical Prototyping 15, no. 1: 22-34.