Topology Optimization Design and Partitioning Methods for Multi-axis Support-free Printing

This paper explores the synergy of topology optimization and partitioning printing in multi-axis support-free printing. Traditional three-axis printing demands extensive supports for topology-optimized structures, causing low efficiency and high costs. While multi-axis printing enables support-free production via dynamic orientation adjustment, it is usually decoupled from topology optimization design, forming a design-manufacturing bottleneck that restricts its full potential. The research focuses on two core aspects: partitioning printing strategies involving model decomposition based on geometric features and performance requirements, and multi-axis-aware topology optimization. This optimization integrates dynamic overhang angle constraints and material anisotropy modeling to generate self-supporting high-performance structures. Findings show serial processes cause performance loss and higher iteration costs; two-step optimization and similar collaborative methods achieve basic block partitioning-optimization linkage but are limited to simplified 2D models, failing to exploit multi-axis printing’s continuous direction-changing ability. Future research should focus on 3D continuous direction field planning, collision avoidance and complex geometry adaptation to advance this technology’s practical application.