The lattice structure configuration design for stereolithography investment casting pattern using topology optimization

Purpose - The purpose of this paper is to introduce, for the first time, the topology optimization method into the lattice structure configuration design for rapid casting patterns. Design/methodology/approach - A structural topology optimization procedure in combination with thermo-mechanical finite element analysis for the lattice structure configuration design has been developed. Findings - A new mixed stress-compliance optimization model is proposed for the strength and rigidity design. Numerical modeling about the mathematical formulation of the objective function and design constraints is established and an optimal material layout inside a given domain of the stereolithography (SL) resin pattern is found. Originality/value - Various optimal results of lattice structure configurations are obtained numerically. By comparing the optimal designs with the existing lattice structure configurations, the newly obtained designs have shown better performances both in reducing the stress in the ceramic shell and in maintaining the stiffness of the SL pattern.