Discrete Space-time Topology Optimization for Wire and Arc Additive Manufacturing (WAAM)

• Grant number: 26/23366-0
• Support Opportunities: Scholarships in Brazil - Master
• Start date: October 01, 2026
• End date: September 30, 2028
• Field of knowledge: Engineering - Naval and Oceanic Engineering - Marine and Ocean Structures
• Principal Investigator: Renato Picelli Sanches
• Grantee: Davi Kauê de Sousa Gomes
• Host Institution: Escola Politécnica (EP). Universidade de São Paulo (USP). São Paulo , SP, Brazil
• Company: Universidade de São Paulo (USP). Escola Politécnica (EP)
• Associated research grant: 22/03698-8 - OTIC Offshore Technology Innovation Centre, AP.PCPE

Abstract

This project proposes the development of a novel topology optimization (TO) framework tailored for additive manufacturing (AM), with particular emphasis on discrete (binary) design variables and process-induced anisotropy. The approach aims to overcome limitations of conventional design methodologies by integrating manufacturing constraints directly into the optimization process, enabling the generation of high-performance and manufacturable structures. The research focuses on advancing space-time TO formulations to simultaneously optimize structural layouts and fabrication sequences, while accounting for key additive manufacturing features such as anisotropic material behavior and process-dependent characteristics. Special attention is given to the incorporation of geometric and process constraints within a unified and computationally efficient framework based on the TOBS methodology. The proposed methods will be assessed through numerical experiments, including finite element simulations under representative loading conditions, to evaluate structural performance and manufacturability. Overall, the project is expected to provide a robust and flexible computational framework, contributing to the development of efficient, lightweight, and manufacturing-aware structural designs. (AU)