Topology Optimization for Lightweight Structures

What we do

We use topology optimization to remove non-functional mass while keeping stiffness, strength and manufacturability. From brackets and frames to robot grippers and housings, we design lightweight parts that pass FEA checks and deliver clean, production-ready CAD instead of just a mesh.

Results we aim for

  • Weight reduction in the range of 20–60 percent with equal or higher stiffness and strength
  • Verified safety factors and modal targets so that no new resonances are introduced
  • Designs suitable for CNC machining, injection molding, casting and additive manufacturing
  • Supplier-ready results: NURBS CAD, drawings and an FEA report

Services

  • Problem framing and load cases – definition of objectives such as minimum mass or maximum stiffness, load cases, boundary conditions, keep-in and keep-out regions and symmetries.

  • Topology optimization – SIMP or level-set based workflows and generative approaches with minimum feature size, pull directions and overhang limits for AM.

  • CAD reconstruction – smooth, fully parametric NURBS surfaces and solids derived from the topology result, including fillets, chamfers and draft features.

  • DFM constraints:

    • CNC: tool access, minimum radii and practical 3- or 5-axis setups
    • Injection molding and casting: parting lines, draft angles, cores and uniform wall thicknesses
    • Additive manufacturing: overhang angle limits, minimum wall and strut size, lattice infill and support strategy

  • Verification FEA – static and nonlinear analyses, buckling, modal and harmonic response, fatigue checks and local smoothing of hotspots where necessary.

  • Lattice and infill design – gyroid and other TPMS structures or strut-based lattices with density maps for AM, including stiffness versus damping trade-offs.

  • Documentation and handover – drawings with GD&T, bill of materials and implementation guidelines for suppliers.

Your deliverables

  • Topology result and clean CAD: dense STEP or Parasolid plus native CAD models for major systems such as SolidWorks, NX, Creo, CATIA or Onshape
  • Engineering report (PDF) with before-and-after metrics, FEA plots, safety factors and modal margins
  • Manufacturing pack: drawings in PDF and DXF or DWG, tolerances, draft and parting information and tooling notes
  • Optional AM pack: lattice parameters, build orientation and support recommendations plus 3MF or STL files for print trials
  • Change log and key parameters so future design revisions can reuse the optimization setup and constraints
  • Handover session of 45–90 minutes with walkthrough and Q&A

Technology stack

  • Optimization and FEA: tools such as OptiStruct, Abaqus with Tosca, Ansys Mechanical, Siemens NX topology optimization and Fusion 360 generative design
  • Latticing and AM preparation with tools such as nTopology and Materialise 3-matic
  • CAD and postprocessing in SolidWorks, NX, Creo, CATIA V5 and Onshape
  • Analysis types as required: static and nonlinear, buckling, modal and harmonic, fatigue using S-N or strain-life approaches and thermomechanical coupling when needed

How collaboration works

  • Discovery (about 30 minutes) – requirements, installation space, interfaces and targets
  • Model and setup – definition of loads, boundary conditions, design space, DFM and AM constraints and acceptance criteria
  • Optimize and rebuild – iterative loop from topology optimization to CAD reconstruction and quick checks
  • Verify – full FEA including fatigue and modal analysis plus a manufacturability review
  • Release – drawings, BOM, supplier notes and a handover session

What we need from you

  • CAD data in STEP or Parasolid, interface definitions, bolt patterns, keep-in and keep-out regions and packaging constraints
  • Load cases with forces, pressures or torques, duty cycles and modal targets where relevant
  • Planned manufacturing route such as CNC, injection molding, casting or additive manufacturing and the intended material
  • Success criteria such as weight, stiffness, natural frequency, safety factor and cost limits

Packages (pricing on request)

  • Lightweighting assessment – quick topology optimization plus before-and-after metrics and risk discussion
  • Optimization sprint – topology optimization, CAD reconstruction, verification FEA and drawings
  • AM advanced – lattice design, print strategy and validation updates for additive parts

Example use cases

  • Mounting bracket: about 45 percent mass reduction, 20 percent higher stiffness, kept fully machinable on three axes
  • Robot end-of-arm tooling: around 35 percent mass reduction, faster cycle times and natural frequencies above the excitation band
  • UAV arm: additive part with lattice core, meeting drop and vibration targets with margin
  • Cast housing: optimised rib layout leading to uniform wall thickness and draft and coring features ready for tooling

FAQ

Do I get editable CAD or only a mesh?
You receive editable, parametric CAD models, not STL-only handovers.

Can strict manufacturing limits be respected?
Yes. Minimum feature sizes, pull directions, parting lines, tool access and overhang limits are enforced during optimization and reconstruction.

Do you consider fatigue and vibration?
Yes. Fatigue and modal or harmonic checks are part of verification, with local smoothing applied where necessary.

Which materials are suitable?
Typical materials include aluminum alloys, steels, titanium for AM, magnesium and reinforced plastics. Constraints are tuned to the chosen manufacturing route.

How do you make sure suppliers can quote reliably?
We provide dimensioned drawings with GD&T and clear process notes. For AM we also include build orientation, support guidance and lattice parameters.

Contact us