A Comparative Analysis of Topology Optimisation and Generative Design Methods for Weight Optimisation

Abstract

Both topology optimisation and generative design are weight optimisation methods that optimise the material layout in a given design space. Topology optimisation has been widely used in various industries over the last few decades. It is a product optimisation technique that removes dispensable material from a solid object using a finite element method (FEM). On the other hand, generative design is a new paradigm in the engineering industry that helps engineers explore variant potential design solutions beyond the capabilities of traditional design processes. As opposed to topology optimisation, the generative design method utilises artificial intelligence and advanced algorithms to generate a series of possible solutions that satisfy the input parameters from an empty design space. The research focuses on comparing the two product optimisation methods by applying them to the same objects. A case study was first conducted to get familiar with the optimisation software. All optimisation and comparison processes were completed in the simulation environment. It shows that designers could obtain a better result by generative design than topology optimisation. Then the main research project absorbed the learnings from the case study and applied both optimisation methods to a shelf bracket. The optimised bracket’s structure has organic appearance with complex geometries, so additive manufacturing is the most suitable method for fabrication. By comparing the simulation and validation results from various aspects such as the simulation process, design space and optimisation results, generative design is a more powerful and efficient tool than topology optimisation. However, from a broader perspective, both topology optimisation and generative design have their use nowadays. Nevertheless, generative design technology will become a more advanced and dominant method for weight optimisation and product development in the future. Moreover, humans should always be kept in the design loop, and the optimised product should always be validated before mass production.