We are excited to share our latest publication on advancing structural optimization in additive manufacturing, co-authored by Iman Valizadeh, Jasper Schommartz and Oliver Weeger.

Using grayscale-masked stereolithography (gMSLA), we developed a novel framework that fine-tunes grayscale levels to control material properties, thereby reducing stress concentrations and enhancing structural integrity. By integrating finite element analysis with gradient-based optimization, our method achieves optimal material distributions that significantly minimize plastic deformation and improve mechanical performance. Experimental results validate the approach, showcasing the potential of grayscale optimization for creating lightweight, high-performance structures.

This work highlights how coupling optimization algorithms with advanced 3D printing can push the boundaries of design freedom and material efficiency in modern engineering.

Check-out the Open Access publication in “Progress in Additive Manufacturing”:
https://doi.org/10.1007/s40964-025-01326-8