Sensitivity Analysis and Filtering of Machinable Parts Using Density-Based Topology Optimization

Topology optimization has become a popular tool for designing optimal shapes while meeting specific objectives and restrictions. However, the resulting shape from the optimization process may not be easy to manufacture using typical methods like machining and may require interpretation and validation. Additionally, the final shape depends on chosen parameters. In this study, we conduct a sensitivity analysis of the main parameters involved in 3D topology optimization—penalization and filter radius—focusing on the density-based method. We analyze the features and characteristics of the results, concluding that a machinable and low interpretable part is not an attainable result in by-default topology optimization. Therefore, we propose a new method for obtaining more manufacturable and easily interpretable parts. The main goal is to assist designers in choosing appropriate parameters and understanding what to consider when seeking optimized shapes, giving them a new plug-and-play tool for manufacturable designs. We chose the density-based topology optimization method due to its popularity in commercial packages, and the conclusions may directly influence designers’ work. Finally, we verify the study results through different cases to ensure the validity of the conclusions.