Temperature Distribution Design Based on Variable Lattice Density Optimization and Metal Additive Manufacturing

Additive manufacturing (AM) is employed for fabricating industrial products with complex geometries. As topological optimization is suitable for designing complex geometries, studies have combined AM and topological optimization, evaluating the density optimization of lattice structures as a variant of topological optimization. The lattice structures of components fabricated via AM comprise voids. Models designed using topological optimization should be modified to ensure structures suitable for AM. As the lattice unit can be easily fabricated using AM with fewer design modifications, this study uses lattice density optimization for an industrial AM product. We propose a method of optimizing the lattice distribution for controlling the surface temperature uniformity of industrial products, such as molds. The effective thermal conductivity of the lattice is calculated using the homogenization and finite element methods. The effective thermal conductivity changes depending on the internal pore sizes. The proposed methodology is validated using a 3D example; the minimization problem of surface temperature variations in the target domain is considered. The variable density of the embedded lattice in the target domain is optimized, and we experimentally validated the performance of the lattice unit cell and optimal 3D structure using metal powder bed fusion AM.