Thesis Defense: Mikhail Osanov, “Topology Optimization for Additive Manufacturing: from Mechanical Components to Orthopaedic Implants”
THE DEPARTMENT OF CIVIL ENGINEERING
ADVISOR JAMES GUEST, ASSOCIATE PROFESSOR
ANNOUNCE THE THESIS DEFENSE OF
Thursday, September 26, 2019
Shriver Board Room
“Topology Optimization for Additive Manufacturing: from Mechanical Components to Orthopaedic Implants”
Additive Manufacturing (AM) is a free-form fabrication technique that creates structures in a layer-by-layer fashion. Topology Optimization is a free-form, systematic approach to designing structures. These technologies are therefore well-suited for each other, but must be integrated to fully leverage their capabilities. This dissertation seeks to more tightly couple Topology Optimization by proposing several novel algorithms that improve manufacturability of the optimized parts and components. These include cylindrical projection method, which mimics the layer-by-layer nature of Additive Manufacturing processes, and several extensions to overhang projection methods for eliminating support structures, including providing access points for easy removal of support structures, eliminating internal voids, accounting for build plate post-processing costs, and utilizing the overhang constraint within the design of support structures. These algorithms are demonstrated on several design examples and solutions are shown to be directly manufacturable, thereby requiring less post-processing operations that can be time and cost intensive.
The final Chapter of this dissertation is dedicated to the design of femoral implants used in Total Hip Arthroplasty (THA). With the growing number of yearly total joint replacements and the demand for improved mobility and quality of life, the need for high-performance implants is apparent. In this work we seek to alleviate the existing clinical issue of stress shielding, pertinent to current state-of-the-art implants, through new designs using Topology Optimization. We propose a novel Topology Optimization formulation that is capable of addressing regional stress levels in bone by manipulating the topology of the implant, and demonstrate solutions that are predicted to reduce stress shielding effects compared to implants that are currently used in practice.