| Summary: | This paper presents basic procedure on coupled design and simulation process for 3D metal printing. As case study, the selected automotive component is front upright with the proposed material of austenitic stainless steel SS316L. This component is modelled based on real application loads and constraints in order to improve driving performance. Various outcomes are created by using generative design method based on preserve and obstacle geometry, selected materials and additive manufacturing method. Preferred design outcome will undergo smoothing process using T-Spline method and be analysed to identify the weak point at the base and bionic shape. Smoothing procedure will include additional material and sharp edge removal until desired stress and safety factor are achieved. Since 3D metal printing consist of rapid high temperature gradient during printing process, the residual stress and distortion of the final component are to be identified in order to mitigate the imperfection using mechanical analysis from inherent strain direct approach method. This process simulation using numerical computation is conducted to define best build orientation. It is expected that, the coupled design and simulation procedure for 3D metal printing can contribute to lightweight and resource-efficient additive manufacturing process. © 2021, The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd.
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