TopoRestruct – Converting topology optimization results into a design geometry, which meets the requirements for manufacturability, functionality and mechanical stress in the product development process

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Modern methods for topology optimization that are based on the finite element analysis allow a robust and simple calculation of lightweight designs that are suitable for the given mechanical requirements for almost any load case. Despite the possibility of considering production constraints during optimization, the result - represented as a triangulated surface mesh - is merely an abstract design proposal. As a design proposal, this cannot be used directly in the product development process or is usually not feasible in this way. The further design of the product in a parametric associative or feature-based 3D CAD system therefore requires an interpretation and reconstruction of the topology optimization result. When considering the state of the art in research and technology, only methods for the extraction of constructive geometry from topology optimization results are available, which allow either a non-parametric surface based redesign or a parametric redesign which is limited to special cases and does not allow a generalized interpretation. Accordingly, the main objective of this research project is to provide a method for the automated, feature-based CAD redesign of topology optimization results during the development process, which meets the requirements for manufacturability, functionality and mechanical stress.To this end, three essential tasks are carried out in this research project. The development of a method for the complete analysis and decomposition of the topology optimized result mesh in an analytical form (I). This makes it possible to describe the topology of the optimization result mathematically with the aim of geometric design analysis and synthesis. In order to allow an interpretation and restructuring of the decomposition for common manufacturing processes in a functional and stress-related manner, a knowledge base and building blocks with corresponding design and interpretation rules will be developed (II). The final step is the integration of the decomposition methods and the knowledge base together with the building blocks (I and II) into a prototypical application. The application demonstrates the automated redesign of topology optimization results into feature-based CAD geometry and makes the method generally usable (III).At the end of the project, a proven and automated method is available to the product developer that enables the automated conversion of topology optimization results into an engineering design model, which meets the requirements for manufacturability, functionality and mechanical stress.