{"status":"ok","message-type":"work","message-version":"1.0.0","message":{"indexed":{"date-parts":[[2026,4,1]],"date-time":"2026-04-01T04:31:21Z","timestamp":1775017881708,"version":"3.50.1"},"reference-count":51,"publisher":"MDPI AG","issue":"7","license":[{"start":{"date-parts":[[2025,6,29]],"date-time":"2025-06-29T00:00:00Z","timestamp":1751155200000},"content-version":"vor","delay-in-days":0,"URL":"https:\/\/creativecommons.org\/licenses\/by\/4.0\/"}],"funder":[{"name":"PALBIT","award":["PRR-C644864375-00000002"],"award-info":[{"award-number":["PRR-C644864375-00000002"]}]}],"content-domain":{"domain":[],"crossmark-restriction":false},"short-container-title":["Metals"],"abstract":"<jats:p>The rapid growth of the machining market and advancements in additive manufacturing (AM) present new opportunities for innovative tool designs. This preliminary study proposes a design for additive manufacturing (DfAM) approach to redesign a milling cutter head in 17-4 PH stainless steel by integrating topology optimization (TO) and internal coolant channel optimization, enabled by laser powder bed fusion (LPBF). An industrial eight-insert milling cutting tool was reimagined with conformal cooling channels and a lightweight topology-optimized structure. The design process considered LPBF constraints and was iteratively refined using computational fluid dynamics (CFD) and finite element analysis (FEA) to validate fluid flow and structural performance. The optimized milling head achieved approximately 10% weight reduction while improving stiffness (reducing maximum deformation under load from 160 \u03bcm to 151 \u03bcm) and providing enhanced coolant distribution to the cutting inserts. The results demonstrate that combining TO with internal channel design can yield a high-performance and lightweight milling tool that leverages the freedom of additive manufacturing. As proof of concept, this integrated CFD\u2013FEA validation approach under DfAM guidelines highlights a promising pathway toward superior cutting tool designs for industrial applications.<\/jats:p>","DOI":"10.3390\/met15070729","type":"journal-article","created":{"date-parts":[[2025,7,1]],"date-time":"2025-07-01T07:42:06Z","timestamp":1751355726000},"page":"729","update-policy":"https:\/\/doi.org\/10.3390\/mdpi_crossmark_policy","source":"Crossref","is-referenced-by-count":6,"title":["Topology Optimization of a Milling Cutter Head for Additive Manufacturing"],"prefix":"10.3390","volume":"15","author":[{"ORCID":"https:\/\/orcid.org\/0009-0003-0793-4180","authenticated-orcid":false,"given":"Il\u00eddio Brito","family":"Costa","sequence":"first","affiliation":[{"name":"Department of Mechanical Engineering, Faculty of Engineering, University of Porto, R. Dr. Roberto Frias, 4200-465 Porto, Portugal"}]},{"ORCID":"https:\/\/orcid.org\/0009-0004-0580-3758","authenticated-orcid":false,"given":"Bruno Rafael","family":"Cunha","sequence":"additional","affiliation":[{"name":"Department of Mechanical Engineering, Faculty of Engineering, University of Porto, R. Dr. Roberto Frias, 4200-465 Porto, Portugal"}]},{"given":"Jo\u00e3o","family":"Marouvo","sequence":"additional","affiliation":[{"name":"R&D Department, Palbit S.A., P.O. Box 4, Branca, Albergaria-a-Velha, 3854-908 Aveiro, Portugal"}]},{"ORCID":"https:\/\/orcid.org\/0000-0002-5697-4344","authenticated-orcid":false,"given":"Daniel","family":"Figueiredo","sequence":"additional","affiliation":[{"name":"R&D Department, Palbit S.A., P.O. Box 4, Branca, Albergaria-a-Velha, 3854-908 Aveiro, Portugal"}]},{"given":"Bruno Miguel","family":"Guimar\u00e3es","sequence":"additional","affiliation":[{"name":"R&D Department, Palbit S.A., P.O. Box 4, Branca, Albergaria-a-Velha, 3854-908 Aveiro, Portugal"}]},{"ORCID":"https:\/\/orcid.org\/0000-0002-3667-0562","authenticated-orcid":false,"given":"Manuel Fernando","family":"Vieira","sequence":"additional","affiliation":[{"name":"Department of Mechanical Engineering, Faculty of Engineering, University of Porto, R. Dr. Roberto Frias, 4200-465 Porto, Portugal"},{"name":"LAETA\/INEGI, Institute of Science and Innovation in Mechanical and Industrial Engineering, R. Dr. Roberto Frias, 4200-465 Porto, Portugal"}]},{"ORCID":"https:\/\/orcid.org\/0000-0002-1714-4671","authenticated-orcid":false,"given":"Jos\u00e9 Manuel","family":"Costa","sequence":"additional","affiliation":[{"name":"Department of Mechanical Engineering, Faculty of Engineering, University of Porto, R. Dr. Roberto Frias, 4200-465 Porto, Portugal"},{"name":"LAETA\/INEGI, Institute of Science and Innovation in Mechanical and Industrial Engineering, R. Dr. Roberto Frias, 4200-465 Porto, Portugal"}]}],"member":"1968","published-online":{"date-parts":[[2025,6,29]]},"reference":[{"key":"ref_1","doi-asserted-by":"crossref","unstructured":"Li, W. (2024). Advanced Manufacturing and Precision Machining. Appl. Sci., 14.","DOI":"10.3390\/app142411642"},{"key":"ref_2","doi-asserted-by":"crossref","first-page":"737","DOI":"10.1016\/j.cirp.2016.05.004","article-title":"Design for Additive Manufacturing: Trends, opportunities, considerations, and constraints","volume":"65","author":"Thompson","year":"2016","journal-title":"CIRP Ann.-Manuf. Technol."},{"key":"ref_3","doi-asserted-by":"crossref","unstructured":"Kelliger, T., Meurer, M., and Bergs, T. (2024). Potentials of Additive Manufacturing for Cutting Tools: A Review of Scientific and Industrial Applications. 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