A longstanding challenge in additive manufacturing (AM), the presence of void regions in additively manufactured components, causes two main issues: the enclosing of build material powder in powder bed fusion techniques and limiting tool access in critical post‐processing operations to remove sacrificial support structures. As topology optimization has embraced and overcome many of the obstacles of incorporating AM constraints into the underlying numerical optimization statement, there exist few solutions that directly address this fundamental void region issue. By developing computationally efficient and effective solutions to this problem, the integration of these two advanced technologies can be fully realized. Drawing on inspiration from the principles of diffusion physics, a particle diffusion void restriction (PDVR) method is presented in this work that is capable of encouraging the optimization scheme to generate final designs that are fully accessible. Additionally, this method empowers the user to choose the type of post‐processing method to clear support material (eg, three‐axis or five‐axis milling operations, number and orientation of part set‐ups) and, therefore, quantify the level of costs associated with the post‐processing operation. The PDVR optimization framework is demonstrated on multiple two‐ and three‐dimensional test problems, with physically manufactured examples depicting the real‐world benefits this method admits.

中文翻译：

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通过扩散物理方法进行增材制造的空隙区域限制

增材制造（AM）中的一项长期挑战是增材制造部件中存在空隙区域，这引起两个主要问题：粉末床融合技术中的建筑材料粉末封闭，以及在关键的后处理操作中限制使用工具以去除牺牲性支撑物结构。由于拓扑优化已包含并克服了将AM约束合并到基本数值优化语句中的许多障碍，因此，很少有解决方案可以直接解决这个基本的空域问题。通过开发计算上有效的解决方案，可以完全实现这两种先进技术的集成。汲取了扩散物理学原理的启发，这项工作提出了一种粒子扩散孔隙限制（PDVR）方法，该方法能够鼓励优化方案生成完全可访问的最终设计。此外，该方法使用户可以选择后处理方法的类型来清除支撑材料（例如，三轴或五轴铣削操作，零件设置的数量和方向），从而量化工件的水平。与后处理操作相关的成本。PDVR优化框架针对多个二维和三维测试问题进行了演示，并以实际制造的示例来描述此方法所带来的实际好处。这种方法使用户可以选择后处理方法的类型来清除支撑材料（例如，三轴或五轴铣削操作，零件设置的数量和方向），从而量化相关的成本水平后处理操作。PDVR优化框架针对多个二维和三维测试问题进行了演示，并以实际制造的示例来描述此方法所带来的实际好处。这种方法使用户可以选择后处理方法的类型来清除支撑材料（例如，三轴或五轴铣削操作，零件设置的数量和方向），从而量化相关的成本水平与后处理操作。PDVR优化框架针对多个二维和三维测试问题进行了演示，并以实际制造的示例来描述此方法所带来的实际好处。