Optimizing 3D printed large-scale structures under worst-case loads

A 3D printer system with a structural optimization tool to generate 3D models optimized for build materials such as those used in binder jetting technology-based printers. The structural optimization tool uses a computational approach to optimize mechanical and mass properties of large-scale structures (i.e., objects to be 3D printed), and the computational approach is tailored for fabrication on binder jetting technologies. To spend a material budget for printing an object wisely, the inventors in designing the computational approach turned the Bresler-Pister failure criterion into an objective measuring the potential of failure of an object or structure. This involved modeling the difference in tensile and compressive strength of the build material. To optimize structures under worst-case loads, the computational approach unifies an optimization to identify worst-case loads with an optimization to minimize the resulting failure potential, nesting them with first-order optimality constraints.