Current Research Status of Self-Supporting Structure Topology Optimization in Additive Manufacturing

In practical additive manufacturing (AM) processes, printed components often involve overhanging structures. Conventional strategies merely generate external support structures in a simplistic manner, which not only significantly impairs printing efficiency but also may compromise the outer surface quality of components during support removal. Unlike traditional approaches, the design and optimization of self-supporting structures can effectively enhance structural stability and foster design innovation throughout the printing process. This paper first outlines the development prospects of additive manufacturing in contemporary industrial contexts, then systematically reviews the latest research progress of topology optimization from two perspectives: continuum structure-based and discrete structure-based methods. Various optimization strategies corresponding to different structural types are summarized and analyzed in detail. As well as, this paper conducts an in-depth study on the design and optimization of self-supporting structures, which holds significant theoretical and engineering importance for enhancing the structural performance, material efficiency, and process feasibility of additive manufacturing.