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New multi-material manufacturing technologies demand the development of new mechanical design approaches, as seen in the production of hybrid components through Tailored Forming. Thereby, a new class of high-performance multi-material parts aiming for enhanced properties, such as lightweight properties, can be constructed and brings with it new challenges. The objective of this paper is to develop a method for finding the optimal material distribution for such multi-material components. Thereunto, Topology Optimization techniques were reviewed, focusing on the progress made on multi-materials and manufacturing constraints implementations. Following, a new method was developed and analyzed, called Interfacial Zone Evolutionary Optimization (IZEO), and here expanded for a multi-material approach. This method makes use of the Evolutionary Algorithms methodology to solve structural optimization problems and provides a flexible way to implement manufacturing constraints. Finally, some cases are presented, in which the developed tool was able to generate a multi-material and manufacturable high-performance design.

An interfacial zone evolutionary optimization method with manufacturing constraints for hybrid components