Page 100 - MSAM-4-1

Materials Science in

Additive Manufacturing

ORIGINAL RESEARCH ARTICLE
Topology optimization of an aluminum bicycle

pedal crank using laser powder bed fusion

Jose Manuel Costa * , Mariana Cerqueira Maia 1 ,Adriana Pinho Fernandes ,
1
1,2
1
Elsa Costa Oliveira ,Manuel Fernando Vieira 1,2 , and
Elsa Wellenkamp Sequeiros 1,2
1 Department of Mechanical Engineering, Faculty of Engineering, University of Porto, Porto, Portugal
2 LAETA, Institute of Science and Innovation in Mechanical and Industrial Engineering, Porto,
Portugal

Abstract

This study investigates the application of topology optimization (TO) in combination
with laser powder bed fusion (LPBF) to design a lightweight, high-performance
bicycle pedal crank using AlSi10Mg alloy. The optimization process was carried
out using Fusion 360 and nTopology, resulting in a 20% mass reduction while
ensuring compliance with the ISO 14781 standards for pedal cranks. The component
was characterized in terms of microstructure, surface roughness, dimensional
*Corresponding author: accuracy, powder distribution, and Vickers hardness. The microstructure exhibited
Jose Manuel Costa the characteristic melt pool patterns associated with LPBF, indicative of the
(jose.costa@fe.up.pt) manufacturing process. Surface roughness measurements showed a mean value
Citation: Costa JM, Maia MC, of 23.4 µm, with dimensional analysis revealing a mean deviation of 7% from
Fernandes AP, Oliveira EC, nominal dimensions. The powder distribution analysis indicated a narrow particle
Vieira MF, Sequeiros EW. Topology size distribution, contributing to consistent print quality. The component’s hardness
optimization of an aluminum bicycle
pedal crank using laser powder was measured at 134 HV0.3, highlighting its promising mechanical properties. This
bed fusion. Mater Sci Add Manuf. work demonstrates the potential of TO and LPBF to produce structurally optimized,
2025;4(1):025040003. lightweight components with enhanced performance, providing valuable insights
doi: 10.36922/MSAM025040003
into the application of Design for Additive Manufacturing for metallic materials.
Received: January 24, 2025
1st revised: February 15, 2025 Keywords: Bike crank; AlSi10Mg; Laser powder bed fusion; Design for Additive
2nd revised: February 18, 2025 Manufacturing; Topology optimization; Metallographic characterization; Roughness
3rd revised: February 20, 2025 dimensional analysis; Powder characterization
Accepted: February 21, 2025
Published online: March 26, 2025
Copyright: © 2025 Author(s). 1. Introduction
This is an Open-Access article Technological advancements continue to revolutionize the manufacturing sector, with
distributed under the terms of the
Creative Commons Attribution additive manufacturing (AM) at the forefront of these innovations. AM is poised to
License, permitting distribution, significantly impact sustainability and society at large, offering transformative solutions
and reproduction in any medium,
1
provided the original work is across various industries. ISO/ASTM 52900:2021 defines AM as joining materials to
properly cited. fabricate parts from three-dimensional (3D) model data, typically layer upon layer,
2,3
Publisher’s Note: AccScience diverging from traditional subtractive and formative manufacturing methodologies.
Publishing remains neutral with This method facilitates the construction of lightweight structures with complex
regard to jurisdictional claims in 4
published maps and institutional geometries by emulating biological processes inspired by biomimetic principles.
affiliations. The principal advantages of AM include diminished production expenses, enhanced

Volume 4 Issue 1 (2025) 1 doi: 10.36922/MSAM025040003