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The driver for this research is the development of multi-material additive manufacturing processes that provides the potential for multi-functional parts to be manufactured in a single operation. To exploit the potential benefits of this emergent technology, new design, analysis and optimization methods are needed. This paper proposes a method in which a multifunctional part, consisting of a system, comprised of a number of connected functional components within a mechanical structure, can be optimized. The main contribution of this paper is the coupling strategy that enables the structural topology optimization (TO) of a part to be carried out in conjunction with the internal system design. This is achieved by accommodating the effects of system integration on the structural response of the part within TO. The method is demonstrated by performing a coupled optimization on a cantilever plate with integrated components and circuitry. The results demonstrate that the method is capable of designing an optimized multifunctional part in which both the structural and system requirements are considered.

A METHOD FOR BI-DIRECTIONAL COUPLING OF STRUCTURE AND SYSTEM IN THE OPTIMISATION OF MULTI-FUNCTIONAL COMPONENTS