This work investigates design analysis and optimization methods for the integration of active internal systems into a component for manufacture using multi-material 3D printing processes. This enables efficient design of optimal multifunctional components that exploit the design freedoms of additive manufacturing (AM). The main contributions of this paper are in two areas: 1) the automated placement and routing of electrical systems within the component volume and, 2) the accommodation of the effect of this system integration on the structural response of the part through structural topology optimization (TO). A novel voxel modeling approach was used to facilitate design flexibility and to allow direct mapping to the 3D printer jetting nozzles.
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