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Multiscale topology optimization with build-orientation coupling for fused filament fabrication
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DOI：10.1007/s40964-026-01878-3.png)
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Abstract
En 中文
Fused filament fabrication (FFF) enables the fabrication of lightweight polymer structures with complex geometries; however, the mechanical performance of printed parts is strongly affected by build orientation and the associated anisotropic stiffness response. Topology-optimized structures designed without considering build-orientation effects may therefore exhibit reduced stiffness or inconsistent load-bearing behavior after fabrication. To address this issue, this study proposes a build-orientation-aware multiscale topology optimization framework for FFF structures. In the proposed framework, the macroscopic material layout, microscopic unit-cell configuration, and build orientation are coupled through an energy-based homogenization scheme. The homogenized stiffness tensor of the representative volume element is transformed according to the prescribed build orientation and incorporated into the macroscopic finite element analysis and optimization procedure. The framework is demonstrated using a Messerschmitt–Bölkow–Blohm beam benchmark. The effects of build orientation and macro–micro material allocation are analyzed numerically, and the optimized design is further reconstructed using nTopology and fabricated by FFF for compression testing. The numerical results indicate that the build-orientation-aware multiscale design reduces the compliance-related strain energy by approximately 20% compared with the baseline orientation case under the investigated setting. Compression tests on PLA and PA6-CF specimens printed at different build orientations show consistent orientation-dependent trends, with the numerically favored orientation showing the highest mean initial stiffness and peak load among the tested groups under the investigated compression condition. These results demonstrate the feasibility of incorporating build orientation into multiscale structural design for FFF. The present validation is limited to a beam-type benchmark, compression loading, and effective stiffness-level anisotropy modeling; nevertheless, the study provides a practical design route for improving the mechanical efficiency and manufacturability of FFF structures.
Keywords:
Fused filament fabrication
Multiscale topology optimization
Build orientation
Energy-based homogenization
Compression validation
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