Additive Manufactured Optimized C-Beam

Additive Manufactured Optimized C-Beam | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Short Report Additive Manufactured Optimized C-Beam Md Mahmudur Rahman This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-8515496/v1 This work is licensed under a CC BY 4.0 License Status: Posted Version 1 posted You are reading this latest preprint version Abstract This project designed, topology-optimized, and fabricated a lightweight C‑beam using fused filament fabrication (FFF) while enforcing support‑free manufacturability and stiffness under a prescribed load. A baseline C‑beam design was analyzed, followed by density‑based topology optimization to maximize stiffness at a 25% volume fraction. Although a PolyNURBS reconstruction captured optimized load paths, its internal overhangs required extensive supports and increased mass. A redesign inspired by the optimized topology preserved the primary load-carrying members while eliminating unsupported features for support‑free printing. The final geometry was printed in PLA using a 0.4 mm nozzle and 0.2 mm layer height, achieving a mass of 46 g. Finite element analysis and physical load testing confirmed that the redesigned beam maintained structural integrity with no visible damage, demonstrating the practical value of AM‑informed design that balances topology optimization results with manufacturability constraints. A cost comparison further indicated large savings for FFF relative to CNC machining for this low-volume custom component. Mechanical Engineering Figures Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 1. Introduction The objective of this project was to design, optimize, and fabricate a lightweight structural beam subjected to a certain loading condition using additive manufacturing (AM). The design problem focused on minimizing mass while maintaining sufficient stiffness and structural performance under a prescribed loading condition. The project constraints included: (1) material efficiency, (2) manufacturability via Fused Filament Fabrication (FFF), and (3) support-free fabrication to reduce waste and post-processing. Related work has demonstrated the integration of topology optimization with extrusion-based AM for lightweight beams, including manufacturability refinement and cost analysis [ 13 ]. Additive manufacturing adoption has also been examined for functional marine components and spare parts fabricated via FFF, illustrating broader application contexts [ 11 ], [ 12 ]. Topology optimization was performed to identify a geometry that efficiently carried load using material only where structurally necessary. Initial optimization results provided a lattice-like structure that reduced mass. but contained numerous unsupported overhangs. A Polynurbs-based geometry reconstruction was generated to support manufacturable lightweight designs for additive manufacturing; however, it exceeded 50 g in mass and required extensive support material, making it unsuitable given project constraints. Consequently, a new design was developed based on the optimized load paths but simplified to enable support-free fabrication and meet weight requirements. The final part was fabricated in polylactic acid (PLA) and tested experimentally to validate performance. Both physical testing and stress analysis and deflection confirmed that the new geometry achieved the desired structural integrity while reducing mass to 46 g, demonstrating the effectiveness of AM-informed structural design. 2. Additive Manufacturing The beam was fabricated using Fused Filament Fabrication (FFF), a thermoplastic extrusion-based AM process. FFF operates by depositing layers of molten thermoplastic polymer through one or more heated extrusion nozzles with a small orifice. In this process, polymer feedstock, typically provided as filament, is heated above its melting temperature, which transforms into a viscous state and is extruded onto a build platform in successive layers according to toolpaths generated from a digital model. The process relies on coordinated motion of the build plate and extrusion head to form complex geometries without the need for molds or subtractive machining. Once deposited, the material cools and solidifies, bonding to the preceding layer. After the completion of each layer, the build platform lowers (or the print head moves upward), allowing the deposition of subsequent layers until the full geometry is formed. Printed layers fuse to form a consolidated part [ 1 ], [ 2 ], [ 3 ]. Recent studies have shown that localized in‑situ thermal energy during FFF can substantially improve layer‑to‑layer bonding and flexural strength in PLA thin‑walled structures while maintaining geometric accuracy [ 7 ]. MEX supports a broad selection of thermoplastic materials, and its straightforward operating principle makes it relatively low-cost, user-friendly, and widely accessible, requiring minimal operator expertise. Additionally, this process can achieve complex geometries with dimensional accuracy and tight tolerances for many engineering applications using [ 4 ]. However, FFF also presents some inherent limitations. Mechanical properties of FFF parts are anisotropic because the layer-by-layer deposition results in directional variations in strength compared to the injection-molded parts. Furthermore, software often randomizes raster orientation between layers to promote in-plane isotropy; the z-direction mechanical properties are generally inferior to those in the x–y plane. Thus, when designing load-bearing parts, it is advantageous to align principal stresses within the plane of higher material strength rather than through the build direction [ 5 ]. These limitations influenced design decisions, particularly the need to avoid unsupported overhangs and to align load paths with filament deposition. Process enhancements such as in‑process annealing and thermal monitoring have been used to mitigate weak Z‑direction bonding and to enable data-driven prediction of toughness and strength in FFF/FDM parts [ 8 ], [ 10 ]. The beam was fabricated using Polylactic Acid (PLA) filament. PLA is suitable for low-to-moderate load prototypes. Its high stiffness-to-density ratio [ 6 ]made it advantageous for creating stiff beams with low mass. FFF provided a feasible method to produce a custom geometry reflecting topology optimization without high tooling cost. Furthermore, the ability to print support-free significantly reduced waste, print time, and post-processing effort. 3. Design and Topology Optimization The design domain consisted of a C-beam with fixed geometric constraints and designated load and boundary locations (Fig. 2 ). The static load analysis of the given geometry (Fig. 3 ) was also performed to compare with the optimized geometry. The need to translate raw topology results into manufacturable geometry (e.g., PolyNURBS reconstruction and support-aware redesign) is consistent with prior topology‑optimized beam studies in extrusion-based AM [ 13 ]. Topology optimization was performed using density-based structural optimization method with a volume fraction target of 25% and ‘maximize stiffness’ that automatically redistributes material within a defined design space to achieve the best structural performance for a selected objective. Several iterations were executed to eliminate stress concentrations and maintain smooth load paths. The optimization produced a shaped structure (Fig. 4 a). Following topology optimization, the geometry was reconstructed using Polynurbs to generate a smooth, manufacturable CAD representation of the optimized volume distribution (Fig. 4 b) that satisfied the imposed displacement and stress limits. Additionally, lattice architecture was introduced into low-stress regions of the optimized geometry to reduce weight while maintaining stiffness, enabling implicit modeling of internal features that preserved the structural performance of the beam (Fig. 4 c). However, the Polynurbs-based geometry imposed additional constraints and resulted in a component with a mass exceeding 50 g (66 g). Moreover, due to multiple internal overhangs and complex curved features, the PolyNurbs model could not be fabricated without extensive support structures, contradicting the project requirements of minimizing material usage and post-processing time. These limitations indicated that the direct use of the Polynurbs model was not feasible and prompted a re-evaluation of the design approach. To overcome these issues, a new geometry was manually designed inspired by the optimized topology (Fig. 6 ). This redesigned model satisfied two critical constraints of the objective a mass below the specified threshold (46 g) and the manufacturability through Fused Filament Fabrication without support structures. Also, the new design preserved the essential load constrains and structural features identified during optimization while simplifying external geometry and eliminating unsupported overhangs. A static load analysis and experimental validation process was conducted to confirm the performance of the redesigned beam. The static load analysis were first performed to evaluate stress distribution, and deformation under the given loading conditions (Fig. 7 ). The static load analysis indicates that the original beam exhibits a peak von Mises stress of approximately 1.32 × 10² lbf/in² with a maximum displacement of about 2.44 × 10⁻³ in, suggesting relatively low stress levels and limited deformation under the applied loading (Fig. 3 ). For the optimized beam, the peak von Mises stress increases to approximately 1.32 × 10⁵ lbf/in², with a corresponding displacement of around 4.09 × 10⁻¹ in (Fig. 7 ), reflecting the redistribution of material into thinner load-bearing members and reduced cross-sectional areas. Despite higher stresses and deformation, the optimized beam achieves a major reduction in mass and channels material along efficient load paths, resulting in a structurally effective lightweight design consistent with the objectives of topology optimization. 3.1 Applicable Design Rules for Additive Manufacturing The following AM-specific rules were applied: Maximum overhang < 45° to eliminate supports Minimum feature size ≥ nozzle diameter Uniform wall thickness for predictable extrusion Fillet transitions to reduce stress concentrations These rules were embedded in the redesign and strongly influenced geometric simplification. 4. Build Preparation After verifying the final design, the STL file was imported into the slicing software ‘Cura’ for build preparation. The ‘Ender 3 S1 Pro’ - a single-extrusion FFF machine, was selected as the printer profile, which automatically defined the available build volume and machine-specific constraints. Printing parameters were then assigned to generate the G-code file for fabrication. The part was produced using Fused Filament Fabrication (FFF) with PLA as the build material, a 0.4 mm diameter nozzle, 0.2 mm layer height, and 100% infill density to ensure adequate structural rigidity. The build plate temperature was set to 60°C, and the print orientation was selected to promote self-supporting features (Fig. 8 ) enabling a support-free build. Once configured, the sliced model was exported as G-code and transferred to the printer for fabrication. Because the print was support-free (Fig. 9 a), post-processing was not needed. Only minor surface smoothing and removal of small edge artifacts were required (Fig. 9 b). No sanding, cutting, or support removal was needed, reducing the potential for geometric distortion. Recent research has used machine learning and large language models to predict and optimize tensile strength across print settings (e.g., nozzle configuration, speed, and part spacing), complementing traditional trial‑and‑error parameter selection [ 8 ], [ 9 ]. 5. Load Testing A physical load testing was performed on the printed prototype to assess the actual structural performance (Fig. 10 ). The beam was placed on top of a flat surface and subjected to the required test load. The part showed no visible deformation, cracking, or delamination, confirming that the optimized topology successfully redistributed stresses along the primary load paths. Both static load analysis results (Fig. 7 ) and experimental testing (Fig. 10 ) demonstrated that the redesigned beam achieved the required mechanical performance, validating that the simplified geometry retained sufficient structural integrity despite significant weight reduction and manufacturability constraints 6. Cost Comparison 6.1. CNC Machining For cost comparison analysis, Protolabs Network (formerly Hubs) | On-demand manufacturing for custom parts arts online website is used to obtain CNC machining quotes for custom parts. Since PLA material is not available for CNC machining on their platform, the quotation was instead generated using ABS, which has a comparable material cost to PLA. Table 1 Cost Analysis of CNC Machining CNC Machining (ABS) Cost Per Unit ($) 673.85 Lead Time 5 Days 6.2 Additive Manufacturing The printing process was carried out using an FFF (Fused Filament Fabrication) printer, which indicated a total runtime of 11 hours. The machine’s operational cost was estimated based on an assumed 500-hour lifespan and a $ 500 purchase price. Considering electricity consumption and other minor expenses as average, the estimated machine operating cost was taken as $ 3 per hour. Table 2 Cost Analysis of Additive Manufacturing Additive Manufacturing (FFF) (PLA) Material Cost ($) 3 Estimated Machine Cost (3$/hr) 33 Total Cost 36 Lead Time 1 Days 7. Conclusion This project illustrates the effectiveness of combining topology optimization with additive manufacturing to produce lightweight, structurally efficient components suitable for engineering applications. Key lessons learned include the need to interpret optimization results rather than replicating them directly and the consideration of manufacturability constraints on final design choices. The earlier optimized version was too heavy and required support material to print, whereas the revised design was lighter, easier to manufacture, and performed much better overall. Future iterations could combine support‑free topology-aware redesign with in‑situ thermal management and data-driven parameter selection to further improve strength and repeatability [ 7 ]–[ 10 ]. References Shaqour B et al (May 2021) Gaining a better understanding of the extrusion process in fused filament fabrication 3D printing: a review. Int J Adv Manuf Technol 114:5–6. 10.1007/s00170-021-06918-6 Siemiński P (2021) Introduction to fused deposition modeling. Additive Manufacturing. Elsevier, pp 217–275. doi: 10.1016/B978-0-12-818411-0.00008-2 . Cuan-Urquizo E, Barocio E, Tejada-Ortigoza V, Pipes RB, Rodriguez CA, Roman-Flores A (2019) ‘Characterization of the Mechanical Properties of FFF Structures and Materials: A Review on the Experimental, Computational and Theoretical Approaches’, Materials , vol. 12, no. 6, p. 895, Mar. 10.3390/ma12060895 Attaran M (2017) ‘The rise of 3-D printing: The advantages of additive manufacturing over traditional manufacturing’, Bus Horiz , vol. 60, no. 5, pp. 677–688, Sep. 10.1016/j.bushor.2017.05.011 Hodder KJ, Nychka JA, Chalaturnyk RJ (2018) ‘Process limitations of 3D printing model rock’, Progress in Additive Manufacturing , vol. 3, no. 3, pp. 173–182, Sep. 10.1007/s40964-018-0042-6 Monaldo E, Ricci M, Marfia S (Feb. 2023) Mechanical properties of 3D printed polylactic acid elements: Experimental and numerical insights. Mech Mater 177:104551. 10.1016/j.mechmat.2022.104551 Patel P, Ahmed R, Shanto TA, Jain A, Taylor RM (2025) Experimental characterization of enhanced fused filament fabrication (FFF) of tall thin–walled structures using polylactic acid (PLA), The International Journal of Advanced Manufacturing Technology, vol. 139, pp. 5663–5675, Aug. 10.1007/s00170-025-16171-w Shanto TA, Shahriar MA, Ahmed T, Zulqernine MJ, Taylor RM (2025) Predicting Mechanical Strength in FDM Printed ABS Parts with In–Process Annealing: A Machine Learning Approach, Proceedings of the IISE Annual Conference & Expo. 10.21872/2025IISE_6734 Shanto TA, Pavel HR, Ahmed R, Abdullah M, Taylor RM (2025) Leveraging Large Language Models for Process Parameter Optimization in 3D–printed ABS Polymer Specimens, Proceedings of the IISE Annual Conference & Expo. 10.21872/2025IISE_6901 Ahmed R, Shanto TA, Rahman MM, Taylor RM, Jain A (2025) Machine Learning–Based Prediction of Toughness in Fused Filament Fabrication. Leveraging In–Process Annealing with Enhanced Printheads, manuscript. Department of Mechanical and Aerospace Engineering, University of Texas at Arlington, Arlington, TX, USA Zulkernine MJ, Alam MA, Uddin MR, Dola IS, Shanto TA (2024) An Investigation on the Applications of Additive Manufacturing in the Marine Industry, in Proceedings of MARTEC : The International Conference on Marine Technology, Johor Bahru, Malaysia, Sep. 2024 Ahmed R, Niloy RS, Mozumder MR, Shanto TA (2024) Application of Fused Filament Fabrication in Marine Sector, From Rapid Prototyping to Final Product, in Proceedings of MARTEC 2024: The International Conference on Marine Technology, Johor Bahru, Malaysia, Sep Ahmed R, Shanto TA (2025) Topology Optimization and Additive Manufacturing of Lightweight Cantilever Beams: Design, Fabrication, and Cost Analysis, Research Square preprint, Sep. 10.21203/rs.3.rs-7725660/v1 Additional Declarations The authors declare no competing interests. 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10:37:42","extension":"png","order_by":22,"title":"","display":"","copyAsset":false,"role":"acdc-reference","size":114065,"visible":true,"origin":"","legend":"","description":"","filename":"Onlinefloatimage9.png","url":"https://assets-eu.researchsquare.com/files/rs-8515496/v1/99b177e4d5a29b099afda563.png"},{"id":99692642,"identity":"f5c48b52-b427-4d87-bde5-649a023f09c4","added_by":"auto","created_at":"2026-01-07 10:37:43","extension":"xml","order_by":23,"title":"","display":"","copyAsset":false,"role":"acdc-reference","size":43322,"visible":true,"origin":"","legend":"","description":"","filename":"rs85154960structuring.xml","url":"https://assets-eu.researchsquare.com/files/rs-8515496/v1/d8df2cd3b4155bcdccea770f.xml"},{"id":99692636,"identity":"faae0fda-677d-44e7-a703-e0dd4f1a95cc","added_by":"auto","created_at":"2026-01-07 10:37:42","extension":"html","order_by":24,"title":"","display":"","copyAsset":false,"role":"acdc-reference","size":49859,"visible":true,"origin":"","legend":"","description":"","filename":"earlyproof.html","url":"https://assets-eu.researchsquare.com/files/rs-8515496/v1/327a84071635635054fcc185.html"},{"id":99692610,"identity":"8027a418-9bcd-405a-96e5-9f4257d15854","added_by":"auto","created_at":"2026-01-07 10:37:42","extension":"png","order_by":1,"title":"Figure 1","display":"","copyAsset":false,"role":"figure","size":97115,"visible":true,"origin":"","legend":"\u003cp\u003eSchematic of the fused filament fabrication (FFF) technology [3]\u003c/p\u003e","description":"","filename":"image1.png","url":"https://assets-eu.researchsquare.com/files/rs-8515496/v1/295b1ab09f064f0067dd2a5f.png"},{"id":99692611,"identity":"6c90fb58-56d4-4441-ad4a-4857b08c3f17","added_by":"auto","created_at":"2026-01-07 10:37:42","extension":"png","order_by":2,"title":"Figure 2","display":"","copyAsset":false,"role":"figure","size":78072,"visible":true,"origin":"","legend":"\u003cp\u003eOriginal Beam Model\u003c/p\u003e","description":"","filename":"image2.png","url":"https://assets-eu.researchsquare.com/files/rs-8515496/v1/70e58480206f14a5268c62c4.png"},{"id":99796565,"identity":"e80bd938-6507-4d97-b0ea-8b4bff0a6cc7","added_by":"auto","created_at":"2026-01-08 13:42:45","extension":"png","order_by":3,"title":"Figure 3","display":"","copyAsset":false,"role":"figure","size":293138,"visible":true,"origin":"","legend":"\u003cp\u003eOriginal Beam Model Analysis (a) Strain Analysis (b) Stress Analysis\u003c/p\u003e","description":"","filename":"image3.png","url":"https://assets-eu.researchsquare.com/files/rs-8515496/v1/5f8c6c3c5e33100b0541ae76.png"},{"id":99692613,"identity":"27207cf2-10b4-40c1-8a24-24dfad269af6","added_by":"auto","created_at":"2026-01-07 10:37:42","extension":"png","order_by":4,"title":"Figure 4","display":"","copyAsset":false,"role":"figure","size":404490,"visible":true,"origin":"","legend":"\u003cp\u003e(a) Optimized Geometry (b) Geometry using Polynurbs (c) Lattice Structure\u003c/p\u003e","description":"","filename":"image4.png","url":"https://assets-eu.researchsquare.com/files/rs-8515496/v1/9b3632ad5bb302bd155758d0.png"},{"id":99796225,"identity":"577cd1bd-7b5f-4e25-842c-9af3a0886f55","added_by":"auto","created_at":"2026-01-08 13:40:46","extension":"png","order_by":5,"title":"Figure 5","display":"","copyAsset":false,"role":"figure","size":374881,"visible":true,"origin":"","legend":"\u003cp\u003eOptimized Beam (Polynurbs) Analysis (a) Strain Analysis (b) Stress Analysis\u003c/p\u003e","description":"","filename":"image5.png","url":"https://assets-eu.researchsquare.com/files/rs-8515496/v1/8008bfe1398f4056f5f65e84.png"},{"id":99795790,"identity":"a1cb8e5e-8745-4310-8c06-2e7cc9453b57","added_by":"auto","created_at":"2026-01-08 13:39:42","extension":"png","order_by":6,"title":"Figure 6","display":"","copyAsset":false,"role":"figure","size":157830,"visible":true,"origin":"","legend":"\u003cp\u003eManually Designed Geometry using CAD Software\u003c/p\u003e","description":"","filename":"image6.png","url":"https://assets-eu.researchsquare.com/files/rs-8515496/v1/6569cffb37091d9cb42d2cb5.png"},{"id":99795227,"identity":"4b5d1485-5df3-4d9b-9737-3a5a194faa44","added_by":"auto","created_at":"2026-01-08 13:37:30","extension":"png","order_by":7,"title":"Figure 7","display":"","copyAsset":false,"role":"figure","size":472522,"visible":true,"origin":"","legend":"\u003cp\u003eNew Design Analysis (a) Stress Analysis (b) Strain Analysis\u003c/p\u003e","description":"","filename":"image7.png","url":"https://assets-eu.researchsquare.com/files/rs-8515496/v1/e1ca9adc4790a5239c37d5e5.png"},{"id":99692620,"identity":"fa88e6d9-259c-4620-b1bf-4caea6470c58","added_by":"auto","created_at":"2026-01-07 10:37:42","extension":"png","order_by":8,"title":"Figure 8","display":"","copyAsset":false,"role":"figure","size":310819,"visible":true,"origin":"","legend":"\u003cp\u003eSTL Mesh Geometry in Slicing Software\u003c/p\u003e","description":"","filename":"image8.png","url":"https://assets-eu.researchsquare.com/files/rs-8515496/v1/91e6bf9d3995d2698f7f6fb3.png"},{"id":99796720,"identity":"cc0eaa40-5a7d-41be-8df5-39c2fde37230","added_by":"auto","created_at":"2026-01-08 13:43:16","extension":"png","order_by":9,"title":"Figure 9","display":"","copyAsset":false,"role":"figure","size":155412,"visible":true,"origin":"","legend":"\u003cp\u003e(a) Printing on Build Plate (b) Final Printed Part\u003c/p\u003e","description":"","filename":"image9.png","url":"https://assets-eu.researchsquare.com/files/rs-8515496/v1/e8761c0e6aa69b95d0a74b49.png"},{"id":99795108,"identity":"cb0175b9-f35f-4014-9cf9-7ec3420dec0c","added_by":"auto","created_at":"2026-01-08 13:37:00","extension":"png","order_by":10,"title":"Figure 10","display":"","copyAsset":false,"role":"figure","size":870896,"visible":true,"origin":"","legend":"\u003cp\u003ePhysical Load Testing\u003c/p\u003e","description":"","filename":"image10.png","url":"https://assets-eu.researchsquare.com/files/rs-8515496/v1/7e3fba07910413b2770ea013.png"},{"id":99805031,"identity":"8751d007-f80b-40d2-abf9-75ed96be35e7","added_by":"auto","created_at":"2026-01-08 14:15:31","extension":"pdf","order_by":0,"title":"","display":"","copyAsset":false,"role":"manuscript-pdf","size":3641588,"visible":true,"origin":"","legend":"","description":"","filename":"manuscript.pdf","url":"https://assets-eu.researchsquare.com/files/rs-8515496/v1/b1d63671-f384-4ae6-a46a-6351bc861e3c.pdf"}],"financialInterests":"The authors declare no competing interests.","formattedTitle":"\u003cp\u003e\u003cstrong\u003eAdditive Manufactured Optimized C-Beam\u003c/strong\u003e\u003c/p\u003e","fulltext":[{"header":"1. Introduction","content":"\u003cp\u003eThe objective of this project was to design, optimize, and fabricate a lightweight structural beam subjected to a certain loading condition using additive manufacturing (AM). The design problem focused on minimizing mass while maintaining sufficient stiffness and structural performance under a prescribed loading condition. The project constraints included: (1) material efficiency, (2) manufacturability via Fused Filament Fabrication (FFF), and (3) support-free fabrication to reduce waste and post-processing. Related work has demonstrated the integration of topology optimization with extrusion-based AM for lightweight beams, including manufacturability refinement and cost analysis [\u003cspan citationid=\"CR13\" class=\"CitationRef\"\u003e13\u003c/span\u003e]. Additive manufacturing adoption has also been examined for functional marine components and spare parts fabricated via FFF, illustrating broader application contexts [\u003cspan citationid=\"CR11\" class=\"CitationRef\"\u003e11\u003c/span\u003e], [\u003cspan citationid=\"CR12\" class=\"CitationRef\"\u003e12\u003c/span\u003e].\u003c/p\u003e \u003cp\u003eTopology optimization was performed to identify a geometry that efficiently carried load using material only where structurally necessary. Initial optimization results provided a lattice-like structure that reduced mass. but contained numerous unsupported overhangs. A Polynurbs-based geometry reconstruction was generated to support manufacturable lightweight designs for additive manufacturing; however, it exceeded 50 g in mass and required extensive support material, making it unsuitable given project constraints.\u003c/p\u003e \u003cp\u003eConsequently, a new design was developed based on the optimized load paths but simplified to enable support-free fabrication and meet weight requirements. The final part was fabricated in polylactic acid (PLA) and tested experimentally to validate performance. Both physical testing and stress analysis and deflection confirmed that the new geometry achieved the desired structural integrity while reducing mass to 46 g, demonstrating the effectiveness of AM-informed structural design.\u003c/p\u003e"},{"header":"2. Additive Manufacturing","content":"\u003cp\u003eThe beam was fabricated using Fused Filament Fabrication (FFF), a thermoplastic extrusion-based AM process. FFF operates by depositing layers of molten thermoplastic polymer through one or more heated extrusion nozzles with a small orifice. In this process, polymer feedstock, typically provided as filament, is heated above its melting temperature, which transforms into a viscous state and is extruded onto a build platform in successive layers according to toolpaths generated from a digital model. The process relies on coordinated motion of the build plate and extrusion head to form complex geometries without the need for molds or subtractive machining. Once deposited, the material cools and solidifies, bonding to the preceding layer. After the completion of each layer, the build platform lowers (or the print head moves upward), allowing the deposition of subsequent layers until the full geometry is formed. Printed layers fuse to form a consolidated part [\u003cspan citationid=\"CR1\" class=\"CitationRef\"\u003e1\u003c/span\u003e], [\u003cspan citationid=\"CR2\" class=\"CitationRef\"\u003e2\u003c/span\u003e], [\u003cspan citationid=\"CR3\" class=\"CitationRef\"\u003e3\u003c/span\u003e]. Recent studies have shown that localized in‑situ thermal energy during FFF can substantially improve layer‑to‑layer bonding and flexural strength in PLA thin‑walled structures while maintaining geometric accuracy [\u003cspan citationid=\"CR7\" class=\"CitationRef\"\u003e7\u003c/span\u003e].\u003c/p\u003e \u003cp\u003eMEX supports a broad selection of thermoplastic materials, and its straightforward operating principle makes it relatively low-cost, user-friendly, and widely accessible, requiring minimal operator expertise. Additionally, this process can achieve complex geometries with dimensional accuracy and tight tolerances for many engineering applications using [\u003cspan citationid=\"CR4\" class=\"CitationRef\"\u003e4\u003c/span\u003e]. However, FFF also presents some inherent limitations. Mechanical properties of FFF parts are anisotropic because the layer-by-layer deposition results in directional variations in strength compared to the injection-molded parts. Furthermore, software often randomizes raster orientation between layers to promote in-plane isotropy; the z-direction mechanical properties are generally inferior to those in the x\u0026ndash;y plane. Thus, when designing load-bearing parts, it is advantageous to align principal stresses within the plane of higher material strength rather than through the build direction [\u003cspan citationid=\"CR5\" class=\"CitationRef\"\u003e5\u003c/span\u003e]. These limitations influenced design decisions, particularly the need to avoid unsupported overhangs and to align load paths with filament deposition. Process enhancements such as in‑process annealing and thermal monitoring have been used to mitigate weak Z‑direction bonding and to enable data-driven prediction of toughness and strength in FFF/FDM parts [\u003cspan citationid=\"CR8\" class=\"CitationRef\"\u003e8\u003c/span\u003e], [\u003cspan citationid=\"CR10\" class=\"CitationRef\"\u003e10\u003c/span\u003e].\u003c/p\u003e \u003cp\u003eThe beam was fabricated using Polylactic Acid (PLA) filament. PLA is suitable for low-to-moderate load prototypes. Its high stiffness-to-density ratio [\u003cspan citationid=\"CR6\" class=\"CitationRef\"\u003e6\u003c/span\u003e]made it advantageous for creating stiff beams with low mass. FFF provided a feasible method to produce a custom geometry reflecting topology optimization without high tooling cost. Furthermore, the ability to print support-free significantly reduced waste, print time, and post-processing effort.\u003c/p\u003e"},{"header":"3. Design and Topology Optimization","content":"\u003cp\u003eThe design domain consisted of a C-beam with fixed geometric constraints and designated load and boundary locations (Fig.\u0026nbsp;\u003cspan refid=\"Fig2\" class=\"InternalRef\"\u003e2\u003c/span\u003e). The static load analysis of the given geometry (Fig.\u0026nbsp;\u003cspan refid=\"Fig3\" class=\"InternalRef\"\u003e3\u003c/span\u003e) was also performed to compare with the optimized geometry. The need to translate raw topology results into manufacturable geometry (e.g., PolyNURBS reconstruction and support-aware redesign) is consistent with prior topology‑optimized beam studies in extrusion-based AM [\u003cspan citationid=\"CR13\" class=\"CitationRef\"\u003e13\u003c/span\u003e].\u003c/p\u003e \u003cp\u003eTopology optimization was performed using density-based structural optimization method with a volume fraction target of 25% and \u0026lsquo;maximize stiffness\u0026rsquo; that automatically redistributes material within a defined design space to achieve the best structural performance for a selected objective. Several iterations were executed to eliminate stress concentrations and maintain smooth load paths. The optimization produced a shaped structure (Fig.\u0026nbsp;\u003cspan refid=\"Fig4\" class=\"InternalRef\"\u003e4\u003c/span\u003ea). Following topology optimization, the geometry was reconstructed using Polynurbs to generate a smooth, manufacturable CAD representation of the optimized volume distribution (Fig.\u0026nbsp;\u003cspan refid=\"Fig4\" class=\"InternalRef\"\u003e4\u003c/span\u003eb) that satisfied the imposed displacement and stress limits. Additionally, lattice architecture was introduced into low-stress regions of the optimized geometry to reduce weight while maintaining stiffness, enabling implicit modeling of internal features that preserved the structural performance of the beam (Fig.\u0026nbsp;\u003cspan refid=\"Fig4\" class=\"InternalRef\"\u003e4\u003c/span\u003ec).\u003c/p\u003e \u003cp\u003eHowever, the Polynurbs-based geometry imposed additional constraints and resulted in a component with a mass exceeding 50 g (66 g). Moreover, due to multiple internal overhangs and complex curved features, the PolyNurbs model could not be fabricated without extensive support structures, contradicting the project requirements of minimizing material usage and post-processing time. These limitations indicated that the direct use of the Polynurbs model was not feasible and prompted a re-evaluation of the design approach. To overcome these issues, a new geometry was manually designed inspired by the optimized topology (Fig.\u0026nbsp;\u003cspan refid=\"Fig6\" class=\"InternalRef\"\u003e6\u003c/span\u003e). This redesigned model satisfied two critical constraints of the objective a mass below the specified threshold (46 g) and the manufacturability through Fused Filament Fabrication without support structures. Also, the new design preserved the essential load constrains and structural features identified during optimization while simplifying external geometry and eliminating unsupported overhangs.\u003c/p\u003e \u003cp\u003eA static load analysis and experimental validation process was conducted to confirm the performance of the redesigned beam. The static load analysis were first performed to evaluate stress distribution, and deformation under the given loading conditions (Fig.\u0026nbsp;\u003cspan refid=\"Fig7\" class=\"InternalRef\"\u003e7\u003c/span\u003e).\u003c/p\u003e \u003cp\u003eThe static load analysis indicates that the original beam exhibits a peak von Mises stress of approximately 1.32 \u0026times; 10\u0026sup2; lbf/in\u0026sup2; with a maximum displacement of about 2.44 \u0026times; 10⁻\u0026sup3; in, suggesting relatively low stress levels and limited deformation under the applied loading (Fig.\u0026nbsp;\u003cspan refid=\"Fig3\" class=\"InternalRef\"\u003e3\u003c/span\u003e). For the optimized beam, the peak von Mises stress increases to approximately 1.32 \u0026times; 10⁵ lbf/in\u0026sup2;, with a corresponding displacement of around 4.09 \u0026times; 10⁻\u0026sup1; in (Fig.\u0026nbsp;\u003cspan refid=\"Fig7\" class=\"InternalRef\"\u003e7\u003c/span\u003e), reflecting the redistribution of material into thinner load-bearing members and reduced cross-sectional areas. Despite higher stresses and deformation, the optimized beam achieves a major reduction in mass and channels material along efficient load paths, resulting in a structurally effective lightweight design consistent with the objectives of topology optimization.\u003c/p\u003e \u003cdiv id=\"Sec4\" class=\"Section2\"\u003e \u003ch2\u003e3.1 Applicable Design Rules for Additive Manufacturing\u003c/h2\u003e \u003cp\u003eThe following AM-specific rules were applied:\u003c/p\u003e \u003cp\u003e \u003cul\u003e \u003cli\u003e \u003cp\u003eMaximum overhang\u0026thinsp;\u0026lt;\u0026thinsp;45\u0026deg; to eliminate supports\u003c/p\u003e \u003c/li\u003e \u003cli\u003e \u003cp\u003eMinimum feature size\u0026thinsp;\u0026ge;\u0026thinsp;nozzle diameter\u003c/p\u003e \u003c/li\u003e \u003cli\u003e \u003cp\u003eUniform wall thickness for predictable extrusion\u003c/p\u003e \u003c/li\u003e \u003cli\u003e \u003cp\u003eFillet transitions to reduce stress concentrations\u003c/p\u003e \u003c/li\u003e \u003c/ul\u003e \u003c/p\u003e \u003cp\u003eThese rules were embedded in the redesign and strongly influenced geometric simplification.\u003c/p\u003e \u003c/div\u003e"},{"header":"4. Build Preparation","content":"\u003cp\u003eAfter verifying the final design, the STL file was imported into the slicing software \u0026lsquo;Cura\u0026rsquo; for build preparation. The \u0026lsquo;Ender 3 S1 Pro\u0026rsquo; - a single-extrusion FFF machine, was selected as the printer profile, which automatically defined the available build volume and machine-specific constraints.\u003c/p\u003e \u003cp\u003ePrinting parameters were then assigned to generate the G-code file for fabrication. The part was produced using Fused Filament Fabrication (FFF) with PLA as the build material, a 0.4 mm diameter nozzle, 0.2 mm layer height, and 100% infill density to ensure adequate structural rigidity. The build plate temperature was set to 60\u0026deg;C, and the print orientation was selected to promote self-supporting features (Fig.\u0026nbsp;\u003cspan refid=\"Fig8\" class=\"InternalRef\"\u003e8\u003c/span\u003e) enabling a support-free build. Once configured, the sliced model was exported as G-code and transferred to the printer for fabrication. Because the print was support-free (Fig.\u0026nbsp;\u003cspan refid=\"Fig9\" class=\"InternalRef\"\u003e9\u003c/span\u003ea), post-processing was not needed. Only minor surface smoothing and removal of small edge artifacts were required (Fig.\u0026nbsp;\u003cspan refid=\"Fig9\" class=\"InternalRef\"\u003e9\u003c/span\u003eb). No sanding, cutting, or support removal was needed, reducing the potential for geometric distortion. Recent research has used machine learning and large language models to predict and optimize tensile strength across print settings (e.g., nozzle configuration, speed, and part spacing), complementing traditional trial‑and‑error parameter selection [\u003cspan citationid=\"CR8\" class=\"CitationRef\"\u003e8\u003c/span\u003e], [\u003cspan citationid=\"CR9\" class=\"CitationRef\"\u003e9\u003c/span\u003e].\u003c/p\u003e"},{"header":"5. Load Testing","content":"\u003cp\u003eA physical load testing was performed on the printed prototype to assess the actual structural performance (Fig.\u0026nbsp;\u003cspan refid=\"Fig10\" class=\"InternalRef\"\u003e10\u003c/span\u003e). The beam was placed on top of a flat surface and subjected to the required test load. The part showed no visible deformation, cracking, or delamination, confirming that the optimized topology successfully redistributed stresses along the primary load paths.\u003c/p\u003e \u003cp\u003eBoth static load analysis results (Fig.\u0026nbsp;\u003cspan refid=\"Fig7\" class=\"InternalRef\"\u003e7\u003c/span\u003e) and experimental testing (Fig.\u0026nbsp;\u003cspan refid=\"Fig10\" class=\"InternalRef\"\u003e10\u003c/span\u003e) demonstrated that the redesigned beam achieved the required mechanical performance, validating that the simplified geometry retained sufficient structural integrity despite significant weight reduction and manufacturability constraints\u003c/p\u003e "},{"header":"6. Cost Comparison","content":"\u003cdiv id=\"Sec8\" class=\"Section2\"\u003e \u003ch2\u003e6.1. CNC Machining\u003c/h2\u003e \u003cp\u003eFor cost comparison analysis, Protolabs Network (formerly Hubs) | On-demand manufacturing for custom parts arts online website is used to obtain CNC machining quotes for custom parts. Since PLA material is not available for CNC machining on their platform, the quotation was instead generated using ABS, which has a comparable material cost to PLA.\u003c/p\u003e \u003cp\u003e \u003cdiv class=\"gridtable\"\u003e\u003ctable float=\"Yes\" id=\"Tab1\" border=\"1\"\u003e \u003ccaption language=\"En\"\u003e \u003cdiv class=\"CaptionNumber\"\u003eTable 1\u003c/div\u003e \u003cdiv class=\"CaptionContent\"\u003e \u003cp\u003eCost Analysis of CNC Machining\u003c/p\u003e \u003c/div\u003e \u003c/caption\u003e \u003ccolgroup cols=\"2\"\u003e \u003cdiv align=\"left\" class=\"colspec\" colname=\"c1\" colnum=\"1\"\u003e\u003c/div\u003e \u003cdiv align=\"left\" class=\"colspec\" colname=\"c2\" colnum=\"2\"\u003e\u003c/div\u003e \u003cthead\u003e \u003ctr\u003e \u003cth align=\"left\" colspan=\"2\" nameend=\"c2\" namest=\"c1\"\u003e \u003cp\u003eCNC Machining (ABS)\u003c/p\u003e \u003c/th\u003e \u003c/tr\u003e \u003c/thead\u003e \u003ctbody\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003eCost Per Unit ($)\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c2\"\u003e \u003cp\u003e673.85\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003eLead Time\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c2\"\u003e \u003cp\u003e5 Days\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003c/tbody\u003e \u003c/colgroup\u003e \u003c/table\u003e\u003c/div\u003e \u003c/p\u003e \u003c/div\u003e \u003cdiv id=\"Sec9\" class=\"Section2\"\u003e \u003ch2\u003e6.2 Additive Manufacturing\u003c/h2\u003e \u003cp\u003eThe printing process was carried out using an FFF (Fused Filament Fabrication) printer, which indicated a total runtime of 11 hours. The machine\u0026rsquo;s operational cost was estimated based on an assumed 500-hour lifespan and a \u003cspan\u003e$\u003c/span\u003e500 purchase price. Considering electricity consumption and other minor expenses as average, the estimated machine operating cost was taken as \u003cspan\u003e$\u003c/span\u003e3 per hour.\u003c/p\u003e \u003cp\u003e \u003cdiv class=\"gridtable\"\u003e\u003ctable float=\"Yes\" id=\"Tab2\" border=\"1\"\u003e \u003ccaption language=\"En\"\u003e \u003cdiv class=\"CaptionNumber\"\u003eTable 2\u003c/div\u003e \u003cdiv class=\"CaptionContent\"\u003e \u003cp\u003eCost Analysis of Additive Manufacturing\u003c/p\u003e \u003c/div\u003e \u003c/caption\u003e \u003ccolgroup cols=\"2\"\u003e \u003cdiv align=\"left\" class=\"colspec\" colname=\"c1\" colnum=\"1\"\u003e\u003c/div\u003e \u003cdiv align=\"left\" class=\"colspec\" colname=\"c2\" colnum=\"2\"\u003e\u003c/div\u003e \u003cthead\u003e \u003ctr\u003e \u003cth align=\"left\" colspan=\"2\" nameend=\"c2\" namest=\"c1\"\u003e \u003cp\u003eAdditive Manufacturing (FFF) (PLA)\u003c/p\u003e \u003c/th\u003e \u003c/tr\u003e \u003c/thead\u003e \u003ctbody\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003eMaterial Cost ($)\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c2\"\u003e \u003cp\u003e3\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003eEstimated Machine Cost (3$/hr)\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c2\"\u003e \u003cp\u003e33\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003eTotal Cost\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c2\"\u003e \u003cp\u003e36\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003eLead Time\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c2\"\u003e \u003cp\u003e1 Days\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003c/tbody\u003e \u003c/colgroup\u003e \u003c/table\u003e\u003c/div\u003e \u003c/p\u003e \u003c/div\u003e"},{"header":"7. Conclusion","content":"\u003cp\u003eThis project illustrates the effectiveness of combining topology optimization with additive manufacturing to produce lightweight, structurally efficient components suitable for engineering applications. Key lessons learned include the need to interpret optimization results rather than replicating them directly and the consideration of manufacturability constraints on final design choices. The earlier optimized version was too heavy and required support material to print, whereas the revised design was lighter, easier to manufacture, and performed much better overall. Future iterations could combine support‑free topology-aware redesign with in‑situ thermal management and data-driven parameter selection to further improve strength and repeatability [\u003cspan additionalcitationids=\"CR8 CR9\" citationid=\"CR7\" class=\"CitationRef\"\u003e7\u003c/span\u003e]\u0026ndash;[\u003cspan citationid=\"CR10\" class=\"CitationRef\"\u003e10\u003c/span\u003e].\u003c/p\u003e"},{"header":"References","content":"\u003col\u003e\u003cli\u003e\u003cspan\u003eShaqour B et al (May 2021) Gaining a better understanding of the extrusion process in fused filament fabrication 3D printing: a review. Int J Adv Manuf Technol 114:5\u0026ndash;6. \u003cspan class=\"ExternalRef\"\u003e\u003cspan class=\"RefSource\"\u003e10.1007/s00170-021-06918-6\u003c/span\u003e\u003cspan address=\"10.1007/s00170-021-06918-6\" targettype=\"DOI\" class=\"RefTarget\"\u003e\u003c/span\u003e\u003c/span\u003e\u003c/span\u003e\u003c/li\u003e \u003cli\u003e\u003cspan\u003eSiemiński P (2021) Introduction to fused deposition modeling. Additive Manufacturing. Elsevier, pp 217\u0026ndash;275. doi: \u003cspan class=\"ExternalRef\"\u003e\u003cspan class=\"RefSource\"\u003e10.1016/B978-0-12-818411-0.00008-2\u003c/span\u003e\u003cspan address=\"10.1016/B978-0-12-818411-0.00008-2\" targettype=\"DOI\" class=\"RefTarget\"\u003e\u003c/span\u003e\u003c/span\u003e.\u003c/span\u003e\u003c/li\u003e \u003cli\u003e\u003cspan\u003eCuan-Urquizo E, Barocio E, Tejada-Ortigoza V, Pipes RB, Rodriguez CA, Roman-Flores A (2019) \u0026lsquo;Characterization of the Mechanical Properties of FFF Structures and Materials: A Review on the Experimental, Computational and Theoretical Approaches\u0026rsquo;, \u003cem\u003eMaterials\u003c/em\u003e, vol. 12, no. 6, p. 895, Mar. \u003cspan class=\"ExternalRef\"\u003e\u003cspan class=\"RefSource\"\u003e10.3390/ma12060895\u003c/span\u003e\u003cspan address=\"10.3390/ma12060895\" targettype=\"DOI\" class=\"RefTarget\"\u003e\u003c/span\u003e\u003c/span\u003e\u003c/span\u003e\u003c/li\u003e \u003cli\u003e\u003cspan\u003eAttaran M (2017) \u0026lsquo;The rise of 3-D printing: The advantages of additive manufacturing over traditional manufacturing\u0026rsquo;, \u003cem\u003eBus Horiz\u003c/em\u003e, vol. 60, no. 5, pp. 677\u0026ndash;688, Sep. \u003cspan class=\"ExternalRef\"\u003e\u003cspan class=\"RefSource\"\u003e10.1016/j.bushor.2017.05.011\u003c/span\u003e\u003cspan address=\"10.1016/j.bushor.2017.05.011\" targettype=\"DOI\" class=\"RefTarget\"\u003e\u003c/span\u003e\u003c/span\u003e\u003c/span\u003e\u003c/li\u003e \u003cli\u003e\u003cspan\u003eHodder KJ, Nychka JA, Chalaturnyk RJ (2018) \u0026lsquo;Process limitations of 3D printing model rock\u0026rsquo;, \u003cem\u003eProgress in Additive Manufacturing\u003c/em\u003e, vol. 3, no. 3, pp. 173\u0026ndash;182, Sep. \u003cspan class=\"ExternalRef\"\u003e\u003cspan class=\"RefSource\"\u003e10.1007/s40964-018-0042-6\u003c/span\u003e\u003cspan address=\"10.1007/s40964-018-0042-6\" targettype=\"DOI\" class=\"RefTarget\"\u003e\u003c/span\u003e\u003c/span\u003e\u003c/span\u003e\u003c/li\u003e \u003cli\u003e\u003cspan\u003eMonaldo E, Ricci M, Marfia S (Feb. 2023) Mechanical properties of 3D printed polylactic acid elements: Experimental and numerical insights. 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Leveraging In\u0026ndash;Process Annealing with Enhanced Printheads, manuscript. Department of Mechanical and Aerospace Engineering, University of Texas at Arlington, Arlington, TX, USA\u003c/span\u003e\u003c/li\u003e \u003cli\u003e\u003cspan\u003eZulkernine MJ, Alam MA, Uddin MR, Dola IS, Shanto TA (2024) An Investigation on the Applications of Additive Manufacturing in the Marine Industry, in Proceedings of MARTEC : The International Conference on Marine Technology, Johor Bahru, Malaysia, Sep. 2024\u003c/span\u003e\u003c/li\u003e \u003cli\u003e\u003cspan\u003eAhmed R, Niloy RS, Mozumder MR, Shanto TA (2024) Application of Fused Filament Fabrication in Marine Sector, From Rapid Prototyping to Final Product, in Proceedings of MARTEC 2024: The International Conference on Marine Technology, Johor Bahru, Malaysia, Sep\u003c/span\u003e\u003c/li\u003e \u003cli\u003e\u003cspan\u003eAhmed R, Shanto TA (2025) Topology Optimization and Additive Manufacturing of Lightweight Cantilever Beams: Design, Fabrication, and Cost Analysis, Research Square preprint, Sep. \u003cspan class=\"ExternalRef\"\u003e\u003cspan class=\"RefSource\"\u003e10.21203/rs.3.rs-7725660/v1\u003c/span\u003e\u003cspan address=\"10.21203/rs.3.rs-7725660/v1\" targettype=\"DOI\" class=\"RefTarget\"\u003e\u003c/span\u003e\u003c/span\u003e\u003c/span\u003e\u003c/li\u003e\u003c/ol\u003e"}],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":true,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":true,"hideJournal":true,"highlight":"","institution":"The University of Texas at Arlington","isAcceptedByJournal":false,"isAuthorSuppliedPdf":false,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":false,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true},"keywords":"","lastPublishedDoi":"10.21203/rs.3.rs-8515496/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-8515496/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003eThis project designed, topology-optimized, and fabricated a lightweight C‑beam using fused filament fabrication (FFF) while enforcing support‑free manufacturability and stiffness under a prescribed load. A baseline C‑beam design was analyzed, followed by density‑based topology optimization to maximize stiffness at a 25% volume fraction. Although a PolyNURBS reconstruction captured optimized load paths, its internal overhangs required extensive supports and increased mass. A redesign inspired by the optimized topology preserved the primary load-carrying members while eliminating unsupported features for support‑free printing. The final geometry was printed in PLA using a 0.4 mm nozzle and 0.2 mm layer height, achieving a mass of 46 g. Finite element analysis and physical load testing confirmed that the redesigned beam maintained structural integrity with no visible damage, demonstrating the practical value of AM‑informed design that balances topology optimization results with manufacturability constraints. A cost comparison further indicated large savings for FFF relative to CNC machining for this low-volume custom component.\u003c/p\u003e","manuscriptTitle":"Additive Manufactured Optimized C-Beam","msid":"","msnumber":"","nonDraftVersions":[{"code":1,"date":"2026-01-07 10:37:37","doi":"10.21203/rs.3.rs-8515496/v1","editorialEvents":[{"type":"communityComments","content":0}],"status":"published","journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true}}],"origin":"","ownerIdentity":"53e7dd48-18d5-4e58-815f-1b7470cf2aaa","owner":[],"postedDate":"January 7th, 2026","published":true,"recentEditorialEvents":[],"rejectedJournal":[],"revision":"","amendment":"","status":"posted","subjectAreas":[{"id":60554476,"name":"Mechanical Engineering"}],"tags":[],"updatedAt":"2026-01-07T10:37:37+00:00","versionOfRecord":[],"versionCreatedAt":"2026-01-07 10:37:37","video":"","vorDoi":"","vorDoiUrl":"","workflowStages":[]},"version":"v1","identity":"rs-8515496","journalConfig":"researchsquare"},"__N_SSP":true},"page":"/article/[identity]/[[...version]]","query":{"redirect":"/article/rs-8515496","identity":"rs-8515496","version":["v1"]},"buildId":"XKTyCvWXoU3ODBz1xrDgd","isFallback":false,"isExperimentalCompile":false,"dynamicIds":[84888],"gssp":true,"scriptLoader":[]}