Additive manufacturing (AM) processes have proven to be a perfect match for topology optimization (TO), as they are able to realize sophisticated geometries in a unique layer-by-layer manner. From a manufacturing viewpoint, however, there is a significant likelihood of process-related defects within complex geometrical features designed by TO. This is because TO seldomly accounts for process constraints and conditions and is typically perceived as a purely geometrical design tool. On the other hand, advanced AM process simulations have shown their potential as reliable tools capable of predicting various process-related conditions and defects. Thus far, geometry design by topology optimization and multiphysics manufacturing simulations have been viewed as two mostly separate paradigms, whereas one should really conceive them as one holistic computational design tool. More specifically, AM process models provide input to physics-based TO, where consequently, not only the designed component will function optimally, but also will have near-to-minimum manufacturing defects. In this regard, we aim at giving a thorough overview of holistic computational design tool concepts applied within AM. First, literature on TO for performance optimization is reviewed and then the most recent developments within physics-based TO techniques related to AM are covered. Process simulations play a pivotal role in the latter type of TO and serve as additional constraints on top of the primary end-user optimization objectives. As a natural consequence of this, a comprehensive and detailed review of non-metallic and metallic additive manufacturing simulations is performed, where the latter is divided into micro-scale and deposition-scale simulations. Material multi-scaling techniques, which are central to the process-structure-property relationships, are reviewed next, followed by a subsection on process multi-scaling techniques, which are reduced-order versions of advanced process models and are incorporable into physics-based TO due to their lower computational requirements. Finally the paper is concluded and suggestions for further research paths discussed.

增材制造 (AM) 工艺已被证明是拓扑优化 (TO) 的完美匹配，因为它们能够以独特的逐层方式实现复杂的几何形状。然而，从制造角度来看，TO 设计的复杂几何特征中很可能存在与工艺相关的缺陷。这是因为 TO 很少考虑工艺约束和条件，并且通常被视为纯粹的几何设计工具。另一方面，先进的增材制造工艺模拟已显示出其作为可靠工具的潜力，能够预测各种与工艺相关的条件和缺陷。到目前为止，通过拓扑优化进行的几何设计和多物理场制造模拟已被视为两个基本独立的范式，然而人们应该真正将它们视为一种整体计算设计工具。更具体地说，增材制造工艺模型为基于物理的 TO 提供输入，因此，设计的组件不仅能够发挥最佳功能，而且制造缺陷也几乎最小化。在这方面，我们的目标是全面概述增材制造中应用的整体计算设计工具概念。首先，回顾了用于性能优化的 TO 文献，然后介绍了与 AM 相关的基于物理的 TO 技术的最新发展。过程模拟在后一种类型的 TO 中发挥着关键作用，并作为主要最终用户优化目标之上的附加约束。作为这种情况的自然结果，对非金属和金属增材制造模拟进行了全面而详细的审查，其中后者分为微观尺度和沉积尺度模拟。接下来回顾材料多尺度技术，它是过程-结构-性能关系的核心，然后是过程多尺度技术的小节，它是高级过程模型的降阶版本，并且可合并到基于物理的模型中。 TO，因为它们的计算要求较低。最后对本文进行了总结并讨论了进一步研究路径的建议。接下来是关于过程多尺度技术的小节，这些技术是高级过程模型的降阶版本，并且由于其较低的计算要求而可合并到基于物理的 TO 中。最后对本文进行了总结并讨论了进一步研究路径的建议。接下来是关于过程多尺度技术的小节，这些技术是高级过程模型的降阶版本，并且由于其较低的计算要求而可合并到基于物理的 TO 中。最后对本文进行了总结并讨论了进一步研究路径的建议。