Performance-Driven Engineering Design Approaches Based on Generative Design and Topology Optimization Tools: A Comparative Study

The advent of Additive Manufacturing (AM) is uncovering the limits of the current CAD systems and, at the same time, is highlighting the potentials of the Topology Optimization (TO) and Generative Design (GD) tools that had not been fully exploited until now. Differently from the traditional design approach in which designers occupy a predominant role in each stage of the design process, the introduction of such tools in the product development process pushes toward simulation-driven design approaches which imply a significant change in the role of the designer. To this end, the paper presents a comparison of two different design methods for Additive Manufacturing based on the adoption of TO and GD tools. The comparison aims to offer a reflection on the evolution of the traditional approach when TO and GD tools are used, and to highlight the potential and limitations of these optimization tools when adopted in an integrated manner with the CAD systems. Furthermore, this comparative study can be a useful and practical source for designers to identify the most appropriate approach to adopt based on their needs and project resources. The comparative study is carried out through the design study of a prototype of a rocker arm and a brake pedal for the Formula Student race car. Their results, compared in terms of mechanical performances, show that both TO and especially GD tools can be efficiently adopted early in a design process oriented to AM to redesign components to make them lighter and stronger.