On the topology optimization design for the stereolithography based investment casting model

The purpose of this paper is to avoid the crack problem of the ceramic shell during the burnout procedure of the rapid investment casting using stereolithograghy (SLA) model. Since the coefficient of thermal expansion of the SLA model is much higher than the coefficient of the ceramic shell, the internal structural patterns have to be properly designed to reduce the stress level in the ceramic shell. A topology optimization method is proposed here to find better microstructure designs to satisfy both the strength of the ceramic shell and the stiffness of the SLA model itself. Taking the arrayed microstructure into account, the pseudo-densities of the SLA model elements to describe the material layout are defined and assumed as the design variables. By deriving the design sensitivities, the topology optimization problem is solved with reasonable numerical results generated.