Topology Optimization for Lightweight Structures

What we do

We use topology optimization to remove non-functional mass while preserving stiffness, strength, and manufacturability. From brackets and frames to robot grippers and housings, we develop lightweight components that pass FEA checks — and we hand over clean, production-ready CAD models instead of just a mesh.

Target outcomes

  • Weight reduction typically in the range of ~20–60% while maintaining equal or higher stiffness and strength

  • Verified safety factors and modal targets, so no new resonances are introduced

  • Designs suitable for CNC machining, injection molding, casting processes, and additive manufacturing

  • Supplier-ready outputs: NURBS CAD, drawing packages, and an FEA report

Services

  • Problem definition & load cases — defining objectives (e.g., minimum mass or maximum stiffness), load cases, boundary conditions, keep-in/keep-out zones, and symmetries.

  • Topology optimization — SIMP- or level-set-based workflows, plus generative approaches with constraints on minimum feature size, draft directions, and overhang limits for additive manufacturing.

  • CAD reconstruction — smooth, fully parametric NURBS surfaces and solid bodies derived from the topology result, including fillets, chamfers, and draft angles.

DFM constraints:

  • CNC: tool accessibility, minimum radii, and practical 3- or 5-axis setups

  • Injection molding & casting: parting lines, draft angles, cores, and as-uniform-as-possible wall thicknesses

  • Additive manufacturing: overhang limits, minimum wall/strut thicknesses, lattice infill, and support strategy

  • Verification FEA — static and nonlinear analyses, buckling, modal and harmonic response, fatigue verification, plus local smoothing of hotspots where required.

  • Lattice & infill design — gyroid and other TPMS structures or strut-based lattices with density gradients for additive manufacturing, including trade-offs between stiffness and damping.

  • Documentation & handover — drawings with GD&T, BOMs, and implementation notes for suppliers.

Your deliverables

  • Topology result & clean CAD: high-quality STEP or Parasolid data plus native CAD models for common systems such as SolidWorks, NX, Creo, CATIA, or Onshape

  • Engineering report (PDF) with before/after metrics, FEA plots, safety factors, and modal margins

  • Manufacturing package: drawings as PDF and DXF/DWG, tolerances, draft and parting-line information, plus notes for toolmaking

  • Optional AM package: lattice parameters, part orientation and support recommendations, plus 3MF or STL files for print trials

  • Change log and key factors so future design changes can reuse the existing optimization setup and boundary conditions

  • 45–90 minute handover session walking through results and Q&A

Technology stack

  • Optimization & FEA: tools such as OptiStruct, Abaqus with Tosca, Ansys Mechanical, Siemens NX topology optimization, and Fusion 360 Generative Design

  • Lattices & AM prep: tools such as nTopology and Materialise 3-matic

  • CAD & post-processing: SolidWorks, NX, Creo, CATIA V5, Onshape

  • Analysis types as needed: static and nonlinear, buckling, modal and harmonic response, fatigue via S–N or strain-life approaches, and thermo-mechanical coupling where required

How we work together

  • Discovery (~30 minutes) — requirements, packaging space, interfaces, and target metrics

  • Model & setup — define loads, boundary conditions, design space, DFM and AM constraints, and acceptance criteria

  • Optimize & rebuild — iterative loop from topology optimization to CAD reconstruction with fast intermediate checks

  • Verify — full FEA including fatigue and modal analysis plus manufacturability assessment

  • Release — drawings, BOM, supplier notes, and handover session

What we need from you

  • CAD data in STEP or Parasolid, interface definitions, hole/bolt patterns, keep-in/keep-out zones, and packaging limits

  • Load cases with forces, pressures, or torques, duty cycles, and modal targets where relevant

  • Planned manufacturing route (CNC, injection molding, casting, or additive manufacturing) and the intended material

  • Success criteria such as weight, stiffness, natural frequencies, safety factors, and cost limits

Packages

  • Lightweighting Assessment — quick topology optimization plus before/after metrics and a risk review

  • Optimization Sprint — topology optimization, CAD reconstruction, verification FEA, and drawing package

  • AM Advanced — lattice design, print strategy, and validation updates for additive parts

Example applications

  • Mounting bracket: ~45% mass reduction, 20% higher stiffness, still fully 3-axis machinable

  • Robot gripper / end-of-arm tooling: ~35% mass reduction, shorter cycle times, and natural frequencies above the excitation range

  • UAV boom: additively manufactured part with lattice core; meets drop and vibration requirements with safety margin

  • Cast housing: optimized rib layout with uniform wall thicknesses, proper draft angles and cores — tool-ready design

FAQ

Do I get editable CAD or only a mesh?
You receive editable, parametric CAD models — not a pure STL/mesh handover.

Can strict manufacturing constraints be met?
Yes. Minimum feature sizes, draft directions, parting lines, tool access, and overhang limits are considered during optimization and reconstruction.

Do you consider fatigue and vibration?
Yes. Fatigue and modal/harmonic checks are part of verification, including local smoothing of critical areas when needed.

Which materials are suitable?
Typical materials include aluminum alloys, steels, titanium (especially for AM), magnesium, and reinforced plastics. Boundary conditions are tailored to the selected manufacturing route.

How do you ensure suppliers can quote reliably?
We deliver dimensioned drawings with GD&T and clear process notes. For AM we also provide orientation, support specs, and lattice parameters.

Contact us