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Meeting 2026 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2026)
Symposium 2026 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2026)
Presentation Title Structural Integrity and Manufacturability Benchmarking of a Generatively Topology-Optimized Component for Metal Additive Manufacturing
Author(s) Zarin Tahsin, Aref Yadollahi, Seyedmostafa Nasrollahpourshirvani, Alex Chojenski, Calvin Mahida, Priyank Panchal, Bradley Rothenberg
On-Site Speaker (Planned) Zarin Tahsin
Abstract Scope Generative topology optimization in metal additive manufacturing (AM) enables the design of load-bearing components with improved structural efficiency by aligning material distribution with primary service load paths. This study investigates a generative topology-optimized brake mounting bracket developed in nTop under realistic service loading and boundary conditions and fabricated in 17-4 PH stainless steel via atomic diffusion additive manufacturing, and benchmarks its performance against an equivalent original solid design configuration. Manufacturability is quantified through comparison of print time, material usage, and cost for both the part and required support structures across all design configurations. Mechanical performance, including tensile and Charpy impact response, is characterized under as-built, H900 heat-treated, and H900 plus hot isostatic pressing conditions and correlated with microstructural evolution and process-induced defects. The results establish structure–process–property relationships linking topology and performance, providing a basis for evaluating tradeoffs between structural efficiency and manufacturing cost.
Proceedings Inclusion? Undecided

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