  This paper presents a multicomponent topology optimization method for
designing structures assembled from additively-manufactured components,
considering anisotropic material behavior for each component due to its build
orientation, distinct material behavior and stress constraint at component
interfaces (i.e., joints). Based upon the multicomponent topology optimization
(MTO) framework, the simultaneous optimization of structural topology, its
partitioning, and the build orientations of each component is achieved, which
maximizes an assembly-level structural stiffness performance subject to maximum
stress constraints at component interfaces. The build orientations of each
component are modeled by its orientation tensor that avoids numerical
instability experienced by the conventional angular representation. A new joint
model is introduced at component interfaces, which enables the identification
of the interface location, the specification of a distinct material tensor, and
imposing maximum stress constraints during optimization. Both 2D and 3D
numerical examples are presented to illustrate the effect of the build
orientation anisotropy and the component interface behavior on the resulting
multicomponent assemblies.
