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Topology optimization (TO) is gaining significant interest in manufacturing, particularly with the rise of additive manufacturing (AM), which allows for the creation of complex geometries. TO eliminates unnecessary material, reducing weight while maintaining performance requirements like stiffness and load capacity. This study utilizes ANSYS software to optimize an eye hook design, analyzing five mass reduction levels (70%, 60%, 50%, 40%, 30%) under a 500N load. The optimized design (TO) is then refined (RTO) to achieve a safety factor of 4. FDM 3D printing with PLA material is used for fabrication, and tensile testing on a Quasar 100 universal testing machine validates the simulation results. Experimental validation confirms the simulation results, demonstrating a significant weight reduction in the TO product from 74.67 g to 34.13 g (48.65%), while maintaining a safety factor of 3.2148. The RTO product, with a mass of 35.77 g, successfully withstands a 750N load for 5 min with a safety factor of 4.

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The Effectiveness of Topology Optimization for Mass Reduction in Fused Deposition Modeling

  • 会议论文

  • 发表日期：

    2026年

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  • Huu Nghi Huynh,
  • Chiet Quan Han,
  • Van Vu Le,
  • Trong Hieu Bui

摘要

Topology optimization (TO) is gaining significant interest in manufacturing, particularly with the rise of additive manufacturing (AM), which allows for the creation of complex geometries. TO eliminates unnecessary material, reducing weight while maintaining performance requirements like stiffness and load capacity. This study utilizes ANSYS software to optimize an eye hook design, analyzing five mass reduction levels (70%, 60%, 50%, 40%, 30%) under a 500N load. The optimized design (TO) is then refined (RTO) to achieve a safety factor of 4. FDM 3D printing with PLA material is used for fabrication, and tensile testing on a Quasar 100 universal testing machine validates the simulation results. Experimental validation confirms the simulation results, demonstrating a significant weight reduction in the TO product from 74.67 g to 34.13 g (48.65%), while maintaining a safety factor of 3.2148. The RTO product, with a mass of 35.77 g, successfully withstands a 750N load for 5 min with a safety factor of 4.