Robust Topology Optimization for Metal Additive Manufacturing Under Process-Induced Anisotropy: A Simulated Lightweight Design Study

This empirical-style article presents a clearly labeled simulated study in Mechanical Engineering. A simulated load- bearing aerospace bracket was optimized under four formulations: conventional compliance minimization, overhang- aware topology optimization, anisotropy-aware optimization, and robust anisotropy-aware optimization. Build angle, elastic anisotropy, yield-strength variation, support volume, mass, compliance, and peak stress were varied across 300 Monte Carlo realizations. No physical component was manufactured. The robust anisotropy-aware design reduced the simulated worst-case stress by 21% relative to the nominal topology-optimized design while retaining a 34% mass reduction versus the unoptimized bracket. The price of robustness was a modest 6% increase in nominal compliance and slightly more support material. The numerical observations, assignments, and measured outcomes are synthetic and intended for methodological illustration only. No real industrial facility, enterprise network, laboratory, construction project, or manufactured component was used. The study demonstrates a realistic research framework aligned with current 2026 research directions while clearly separating simulated evidence from verified literature.