DFAM 301: Topology Optimization
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Design for AM is not about printing an existing part – it is about rethinking geometry around what the technology can do. Topology optimization is the most powerful tool in that direction.
What you will learn
- What DfAM is and why traditional DFM rules do not apply
- Topology optimization principles – the SIMP method
- Defining load cases, constraints and the design space
- Lattice structures – surface, beam, hybrid
- Generative design in Fusion 360 and nTopology
- Validating an optimized result through simulation
- Preparing for SLM, SLS and FDM production
Course outline
- Lesson 1: The DfAM mindset – think by function, not by form
- Lesson 2: Topology optimization – mathematical foundations
- Lesson 3: Defining load cases on a real example
- Lesson 4: Lattice geometry and its mechanical properties
- Lesson 5: Generative design – multi-outcome workflow
- Lesson 6: Simulation-based validation and safety factor
- Lesson 7: Preparation for a specific AM technology
- Lesson 8: Final project – an optimized structural component
Prerequisites
CAD at the level of course-cad101-fusion360, desirable FEA simulation experience, and at least one of course-mat201-eng-polymers or course-pbf301-powder-bed completed.
Outcome
You apply topology optimization in real projects, judge when the analysis time is worth the material savings, and communicate the benefits to non-technical stakeholders.
Who it is for
Senior engineers, R&D leads, aerospace and automotive specialists, and product designers looking to leverage AM technologies.