Session Sheet - 2026 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2026): Applications: Topology Optimization

2026 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2026): Applications: Topology Optimization
Program Organizers: David Leigh, University of Texas at Austin

Tuesday 8:00 AM
August 4, 2026
Room: Lavaca
Location: AT&T Center

8:00 AM
Collision-Aware Topology Optimization (CATO) for Robotic-Enabled Additive Manufacturing: Conner Petru¹; Ronnie Stone¹; Arya Haria¹; Zhenghui Sha¹; ¹University of Texas at Austin
    Topology optimization (TO) is a method for generating designs that satisfy constraints while pursuing specific objectives (e.g., minimizing weight). Existing TO workflows typically focus on structural performance and manufacturability for traditional 3D printing, disregarding robot-enabled AM and assembly. As a result, many automated tasks still require human intervention. One such scenario is robotic arm-enabled FDM, which introduces complex kinematics and collision geometries generally not considered in TO. This requires a TO framework that not only adapts to the component’s fabrication process (e.g., additive), but also to its automation environment. This paper introduces Collision-Aware Topology Optimization (CATO) for Robotic-Enabled Additive Manufacturing, a new TO pipeline that incorporates ROS-based collision feedback to ensure that the generated design can be feasibly manufactured and assembled using robotic arms. By analyzing the performance of this pipeline for robotic-enabled fabrication tasks, we investigate how TO can leverage simulation feedback for future autonomous factories.

8:20 AM
Motivating Redesign and Optimization for Additive Manufacturing – A Part Replacement Case Study: Joseph Kubalak¹; Callie Zawaski¹; ¹Pennsylvania State University Applied Research Lab
    When applying additive manufacturing (AM) to parts designed for other manufacturing process (e.g., part replacement or emergency production), there is often resistance to redesign. Naively printing parts without considering design for AM (DfAM) guidelines typically results in structures that dramatically underperform their original counterparts. Unfortunately, this poor performance is frequently attributed to the AM process itself rather than the underlying design ethos. In this paper, we demonstrate this pitfall in a simple part-replacement case study; a common household item is reproduced via AM using the nominal design and material, but the replacement is extremely fragile compared to the original. By allowing moderate design modifications via topology optimization, the replacement’s performance is significantly improved. We also show that accounting for DfAM guidelines (e.g., critical overhangs and build orientation) further improves performance. Although a relatively simple case study, we hope this exploration helps motivate the need for redesign on more complex structures.

8:40 AM
Structural Integrity and Manufacturability Benchmarking of a Generatively Topology-Optimized Component for Metal Additive Manufacturing: Zarin Tahsin¹; Aref Yadollahi¹; Seyedmostafa Nasrollahpourshirvani¹; Alex Chojenski¹; Calvin Mahida¹; Priyank Panchal¹; Bradley Rothenberg²; ¹Purdue University Northwest; ²nTopology Inc.
    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.

9:00 AM
Design and Fabrication of Optimized Gyroid-Like Structures for Thermal and Mechanical Performance: Myung Kyun Sung¹; Albert To¹; ¹University of Pittsburgh
    While gyroid lattice structures are highly effective for additive manufacturing (AM), offering excellent strength-to-weight ratios and accelerates manufacturing time, they are not inherently tailored to specific applications and require manual thickness adjustments. Topology optimization (TO) can identify optimum material distributions for specific constraints, but it struggles to maintain the seamless, repeating unit cells (periodic boundaries) necessary for printed lattices. To bridge this gap, this study introduces a multi-objective topology optimization method that creates custom "gyroid-like" structures. By enforcing gyroid-like boundary conditions, the method ensures structural continuity while simultaneously optimizing for mechanical strength and thermal efficiency, a success confirmed by experimental results.

9:20 AM
Enhancing Interfacial Integrity in Multi-Material Fabrication via Topology-Optimized Interlocking Joints: Myung Kyun Sung¹; Albert To¹; ¹University of Pittsburgh
    While conventional joining techniques—such as bolting, welding, and adhesives—are widely used, they often suffer from poor environmental durability and limited geometric adaptability when pairing dissimilar materials. Modern engineering demands high-performance, rapidly produced interfaces capable of maintaining integrity under extreme conditions. A significant gap exists, however, in the ability to precisely calibrate interfacial strength and failure behavior through localized geometric design. This research bridges that gap by applying topology optimization to create mechanically interlocking joints specifically for multi-material additive manufacturing. By integrating interfacial weakness directly into the optimization framework, this method produces robust, assembly-free connections that overcome the inherent limitations of traditional material bonding.

9:40 AM Break