A Benchmarking Analysis of Commercial Software for Topology Optimization in Industrial Applications

Topological optimization and generative design are methodologies that can reduce the weight of aerospace and automotive components without worsening stiffness, strength, or natural frequency. The obtained shapes are typically based on complex geometries and can hardly be obtained using traditional working processes, such as chip removal machining; additive manufacturing technologies should be used instead. Several commercial tools are available to design lightweight structures, providing different results when optimization is performed to reduce mass while preserving stiffness or strength. In this paper, a case study is shown to support the wide variety of shapes that can be obtained, and an interview among experts in the field has been carried out to understand the motivations underlying the preference for an optimized model over another one. Those comments can be helpful for software developers to match the users’ requests better and develop the new generation of CAD systems capable of handling lightweight complex shapes.