Topology Optimization of Lattice Support Structure for Cantilever Beams Fabricated Via Laser Powder Bed Fusion

Herein, a numerical scheme is presented to design, optimize, generate, and manufacture a lattice support structure that reduces thermal‐induced distortion in metallic components 3D printed by laser powder bed fusion (LPBF). The inherent strain method is implemented in the framework to fast predict the part distortion during an LPBF build, and asymptotic homogenization is used to determine the effective properties of the lattice support with a triply periodic minimum surface topology. The framework is tested on a practical case study that involves the design of the optimized gradient of a lattice that supports a cantilever beam and compares the results with benchmark designs, a lattice support structure with uniform relative density and a fully solid support. The optimized support can reduce the distortion pattern throughout the entire cantilever beam and reduces the beam tip distortion of 69% and 58% in comparison to the uniform lattice and fully solid support. To demonstrate the viability of the design workflow here presented, a proof‐of‐concept lattice support is manufactured out SS316 stainless steel via LPBF.