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@article{187797,
        author = {K Sri Harsha Reddy and K Durga Rao and B Lakshmi and M Sindhu},
        title = {A Topology-Optimized Approach to Material-Efficient Mechanical Component Design Using Additive Manufacturing},
        journal = {International Journal of Innovative Research in Technology},
        year = {2025},
        volume = {12},
        number = {6},
        pages = {6493-6500},
        issn = {2349-6002},
        url = {https://ijirt.org/article?manuscript=187797},
        abstract = {Additive Manufacturing (AM) offers unprecedented flexibility in producing lightweight, geometrically complex mechanical components that are often unattainable through conventional fabrication routes. This study proposes a comprehensive topology-optimization–driven design framework tailored specifically for AM-enabled mechanical structures, with the objective of maximizing material efficiency while maintaining high structural performance. The methodology begins with the formulation of functional and operational requirements such as load-bearing capability, stiffness criteria, and application-specific constraints followed by the development of an initial CAD model that incorporates AM process limitations, including build orientation, minimum feature size, and support-structure considerations.
Topology optimization is then employed to strategically eliminate low-stress material regions while preserving manufacturability and global structural integrity. The optimized geometry is subsequently validated using finite element analysis (FEA) under realistic loading scenarios, explicitly accounting for AM-related factors such as anisotropic material behavior, process-induced variability, and post-processing influences.
Results demonstrate that the proposed approach achieves significant reductions in material usage without compromising mechanical reliability, underscoring the value of integrating topology optimization with AM-centric design practices. This work highlights the potential of AM-driven optimization strategies in advancing sustainable, high-performance mechanical component development.},
        keywords = {Additive Manufacturing, Topology Optimization, Lightweight Structures, Finite Element Analysis, Structural Reliability, Material Efficiency.},
        month = {November},
        }