  Integrating topology optimization and additive manufacturing (AM) technology
can facilitate innovative product development. However, laser powder bed
fusion, which is the predominant method in metal AM, can lead to issues such as
residual stress and deformation. Recently, topology optimization methods
considering these stresses and deformations have been proposed; however, they
suffer from challenges caused by an increased computational cost. In this
study, we propose a method for reducing computational cost in topology
optimization considering the deformation in AM. An inherent strain method-based
analytical model is presented for simulating the residual stress and
deformation in the AM process. Subsequently, a constraint condition to suppress
the deformation is formulated, and a method to reduce the computational cost of
the adjoint analysis in deriving sensitivity is proposed. The minimum mean
compliance problem considering AM deformation and self-support constraints can
then be incorporated into the level set-based topology optimization framework.
Finally, numerical examples are presented for validating the effectiveness of
the proposed topology optimization method.
