One of the current challenges of the aerospace industry is the exploration of new lightweighting structures to reduce fuel consumption and limiting the environmental impact. The use of numerical methods concerning topology optimization techniques allows the obtaining of such weight reduction, also minimizing both design time and costs, and hence accelerating the design process. Nevertheless, current structural optimization leads to the apparition of complex shapes and volumes with unintuitive holes, thus needing the use of additive manufacturing constraints - minimum length scales and overhanging - to ensure manufacturability. Considering the background exposed above, the aim of this project is to study the feasibility of heuristic designs concerning lightweighting structures, materialized with additive manufacturing and considering 3D printing constraints. The design stage will be developed by means of topology optimization techniques, applied to anisotropic filtering. The methodology employed has considered all details concerning Computational Solid Mechanics (CSM) techniques used in structures optimization, as well as additive manufacturing techniques, different case studies definition and their feasibility study. More specifically, in the context of CSM, the use of Finite Element Methods (FEM) in the classical elastic problem is reviewed, as well as current topology optimization techniques, so as to implement FEM in optimization algorithms. Thus, theoretical basis in additive manufacturing techniques are reviewed, along with the mathematical formulation of length scale and overhang constraints. Lastly, the programming stage is performed by previously defining the working environment, consisting in the use of Object-Oriented Programming within the git Version Control System, and hence establishing the computational domain definition for all cases, the meshing process and the simulation setup. In the end, the present project has accomplished the main objectives, giving a positive answer to the creation of lightweighting structures and fulfillment of 3D printing constraints. Indeed, FEM combined with topology optimization techniques has led to the obtaining of optimized designs, fulfilling an objective function and a set of constraints, considering both design variables approaches, density and level set. Besides, an additional shape functional has been defined as a penalty contribution to the main cost function in order to fulfill 3D printing constraints - the anisotropic perimeter - being the evolution of the standard isotropic one, both applied to total and relative perimeters. This shape functional self-penalizes length scale constraints and keeps control in overhanging phenomena by orienting the topologies with the definition of a virtual anisotropic stiffness matrix. Results obtained show that the apparition of local features with small length scales has been avoided when including either isotropic or anisotropic perimeter as a penalty term. Furthermore, vertical tendency orientation of topologies has been generally obtained with the anisotropic cases, along with penalization of horizontal features. Overall, this project has become clearly relevant for the exploration of new lightweighting structures, achieving weight reduction with topology optimization techniques. Further exploration remains in the course of PhD professionalization, specially when considering phase-field models, high-performance computing and large-scale optimization inside the non-linear regime
