Topology Optimization for Lightweight Design

What we do

We use topology optimization (TopOpt) to remove non-functional mass while preserving stiffness, strength, and manufacturability. From brackets and frames to robot end-effectors and housings, we design lightweight parts that pass FEA—and hand you clean, production-ready CAD (not just a mesh).

Outcomes we target

  • 20–60% weight reduction at equal or higher stiffness/strength

  • Verified safety factors and modal targets (no new resonances)

  • Designs constrained for manufacturing (CNC, molding, casting, AM)

  • Supplier-ready deliverables: NURBS CAD, drawings, and FEA report

Services

  • Problem Framing & Loads – define objectives (min mass/max stiffness), load cases, constraints, keep-ins/keep-outs, symmetry.

  • Topology Optimization – SIMP/level-set or generative workflows with min feature size, draw direction, and overhang limits.

  • CAD Reconstruction – smooth, parametric NURBS surfaces/solids from the topology result; fillets, blends, and draft added.

  • DFM Constraints –

    • CNC: tool access, min radii, 3-axis/5-axis fixtures

    • Molding/Casting: parting lines, draft, coring, uniform walls

    • Additive (AM): overhang ≤ angle, min wall/strut, lattice infill, support strategy

  • Verification FEA – static/nonlinear, buckling, modal/harmonic, fatigue checks; hot-spot smoothing.

  • Lattice & Infill Design – gyroid/TPMS or beam lattices with density maps for AM; stiffness vs. damping trade studies.

  • Documentation & Handoff – drawings with GD&T, BOM, and an implementation guide for suppliers.

Deliverables you receive

  • Topology result + Clean CAD: watertight STEP/Parasolid and native CAD (SW/NX/Creo/CATIA/Onshape)

  • Engineering Report (PDF): before/after metrics, FEA plots, safety factors, modal margins

  • Manufacturing Pack: drawings (PDF + DXF/DWG), tolerance/callouts, draft/parting, tooling notes

  • AM Pack (optional): lattice parameters, orientation/support notes, .3MF/STL for print trials

  • Change Log & Parameters: optimization setup, constraints, and tunables for future revisions

  • Handover Session: 45–90 min walkthrough + Q&A

Technical stack

  • Optimization/FEA: OptiStruct/HyperWorks, Abaqus + Tosca, ANSYS Mechanical, Siemens NX Topology Optimization, Fusion 360 Generative Design

  • Latticing/AM: nTopology, Materialise 3-matic

  • Post/CAD: SolidWorks, NX, Creo, CATIA V5, Onshape

  • Analyses: static/nonlinear, buckling, modal/harmonic, fatigue (S-N/ε-N), thermo-mechanical if needed

How an engagement works

  1. Discovery (30 min) – requirements, envelopes, interfaces, targets.

  2. Model & Setup – loads/BCs, design space, DFM/AM constraints, acceptance criteria.

  3. Optimize & Rebuild – iterate TopOpt → CAD reconstruction → quick checks.

  4. Verify – full FEA (incl. fatigue/modal) and manufacturability review.

  5. Release – drawings/BOM, supplier notes, and handover session.

What we need from you

  • CAD (STEP/Parasolid), interfaces/bolt patterns, keep-ins/outs, envelope limits

  • Load cases (forces, pressures, torque), duty cycles, modal targets

  • Target manufacturing route (CNC / molding / casting / AM) and material

  • Success criteria (weight, stiffness, natural frequency, safety factor, cost)

Packages (price as you prefer)

  • Lightweighting Assessment – quick TopOpt + before/after metrics and risks.

  • Optimization Sprint – TopOpt, CAD reconstruction, verification FEA, drawings.

  • AM Advanced – lattice design, print strategy, and validation updates

Example use cases

  • Mounting bracket: −45% mass, +20% stiffness; 3-axis machinable geometry.

  • Robot EOAT: −35% mass → faster cycles; natural frequency ↑ beyond excitation band.

  • UAV arm: AM + lattice core; drop and vibration targets passed with margin.

  • Cast housing: rib topology → uniform wall thickness; draft/coring ready for tooling.

FAQ

Will I get editable CAD or just a mesh?
Editable parametric CAD is included—no STL-only handoffs.

Can you meet strict manufacturing limits?
Yes—min feature size, draw direction, parting lines, tool access, and overhang limits are enforced during optimization and reconstruction.

Do you account for fatigue and vibration?
Absolutely—fatigue and modal/harmonic checks are part of verification, with local smoothing where needed.

What materials work best?
Al alloys, steels, Ti (AM), Mg, and reinforced plastics; we adapt constraints to the chosen route.

How do you ensure suppliers can quote?
We provide dimensioned drawings, GD&T, and process notes; for AM we include orientation, supports, and lattice parameters.