A robust three-dimensional multiscale topology optimisation framework with concurrent coupling between scales is presented. Concurrent coupling ensures that only the microscale data required to evaluate the macroscale model during each iteration of optimisation is collected and results in considerable computational savings. This represents the principal novelty of the framework and permits a previously intractable number of design variables to be used in the parametrisation of the microscale geometry, which in turn enables accessibility to a greater range of mechanical point properties during optimisation. Additionally, the microscale data collected during optimisation is stored in a re-usable database, further reducing the computational expense of subsequent iterations or entirely new optimisation problems. Application of this methodology enables structures with precise functionally-graded mechanical properties over two-scales to be derived, which satisfy one or multiple functional objectives. For all applications of the framework presented within this thesis, only a small fraction of the microstructure database is required to derive the optimised multiscale solutions, which demonstrates a significant reduction in the computational expense of optimisation in comparison to contemporary sequential frameworks.

The derivation and integration of novel additive manufacturing constraints for open-walled microstructures within the concurrently coupled multiscale topology optimisation framework is also presented. Problematic fabrication features are discouraged through the application of an augmented projection filter and two relaxed binary integral constraints, which prohibit the formation of unsupported members, isolated assemblies of overhanging members and slender members during optimisation. Through the application of these constraints, it is possible to derive self-supporting, hierarchical structures with varying topology, suitable for fabrication through additive manufacturing processes.