Everything you need to know about topology optimization

Making parts lighter can be achieved in various ways. CNC machining services can help achieve this, for example. However, you can also use a stronger or lighter material to make the product lighter. With the help of 3D printing services, complex and light 3D geometries can be created and another design method can be used to create these complex geometries. Topology optimization is a great example of such a design method. Here, material is only used in places where it makes an effective contribution. This results in lightweight and rigid parts. By using topology optimization software, we can make products that are strong and robust with a minimum amount of material. So, just like nature, materials are used as efficiently as possible and produce lightweight parts. 

How did topology optimization start?

Whether it is trees or bones, nature is very efficient with materials and energy. If the environment changes, for example due to soil erosion or felling of trees, the trunk and roots of a tree will adapt to the new circumstance. The same thing happens with bones in your body. Prolonged strenuous exercise ensures that your bones start to strengthen where they are needed. But also the other way around, if you do not exert yourself for a longer period of time, your bones become weaker. That way you don’t carry all that weight around unnecessarily. At the beginning of the 19th century, the German scientist Wolff had already realized that bones adapt to heavy or light exertion. In the nineties this was further investigated and this principle was converted into a computer algorithm called topology optimization.

How does topology optimization work?

Usually manufacturing a product involves applying loads to parts that have already been 3D printed. This is done to evaluate where the product weakens. The design will then be altered by the engineer, which is done until the created part meets the needed mechanical constraints. However, this logic is different in topology optimization. Mechanical loads will represent input data, this will allow the software to propose a new geometry for the product. Because of this, there will be less iterations made to the design, which reduces design and manufacturing lead times and costs. Topology optimization essentially starts with a rough 3D model, which will then be improved by the software. 

What is the best topology optimization software?

Unfortunately not all CAD software offer topology optimization features. Therefore, it definitely is a good idea to opt for a software that does include it. By doing this, you can definitely design an optimal part. However, you could also use dedicated software to achieve this, which has been created by multiple developers. Altair has created the very first OptiStruct solution for example, which was later joined by Altair Inspire too. Other great options are Autodesk, nTopology, Ansys, and Dassault Systèmes. Do you just want to use a CAD software program? In this case, Creo, Solidworks and Fusion 360 are great options. These all include topology optimization features.