Topology optimization has evidenced its capacity to provide new optimal designs in many different disciplines. However, most novel methods are difficult to apply in commercial software, limiting their use in the academic field and hindering their application in the industry. This article presents a new open methodology for solving geometrically complex non-self-adjoint topology optimization problems, including stress-constrained and stress minimization formulations, using validated FEM commercial software. The methodology was validated by comparing the sensitivity analysis with the results obtained through finite differences and solving two benchmark problems with the following optimizers: Optimality Criteria, Method of Moving Asymptotes, Sequential Least-Squares Quadratic Programming (SLSQP), and Trust-constr optimization algorithms. The SLSQP and Trust-constr optimization algorithms obtained better results in stress-minimization problem statements than the methodology available in ABAQUS^®. A Python implementation of this methodology is proposed, working in conjunction with the commercial software ABAQUS^® 2023 to allow a straightforward application to new problems while benefiting from a graphic user interface and validated finite element solver.

The use of 3D printing has proven to have significant benefits to manufacture components with complex geometries with several types of materials and reinforcements for a wide variety of uses including structural applications. The focus of this study is to develop and implement a thermoplastic pultrusion process that can obtain a carbon fiber/polypropylene (CF/PP) filament for a 3D printing process. This development process included the design and finite element analysis of the die used to conform the filament, considering the adaptation of a filament-winding setup to achieve adequate production conditions. The finite element model tried to achieve homogeneous heating of the die with the use of a series of resistors controlled by PID controllers monitoring several thermocouples strategically positioned while the use of water circulating channels was responsible for the cooling effect. The die-heating environment is optimized for different scenarios with different initial temperatures, cooling temperatures, and pulling speeds. A series of experiments were performed under different conditions, such as different heating temperatures and pulling speeds to analyze the quality of the filament produced. The obtained filaments presented an average diameter of 1.94 mm, fiber volume fraction of 43.76%, and void content of 6.97%.