Design optimisation is the process of refining the geometry and structure of designed components to achieve their best performance in terms of strength, weight, cost, and manufacturing efficiency. The optimisation process uses mathematical methods, numerical analysis, and simulation techniques, such as finite element analysis (FEA) and topological optimisation, to achieve the greatest possible functionality while minimising material and production costs. This technique is particularly important in the design of parts for 3D printing, where proper optimisation makes it possible to reduce the amount of material used while maintaining high mechanical strength.
Design Optimization
Type of technology
Description of the technology
Basic elements
- Topological optimisation: The process of modifying the geometry of an object to obtain the best strength with minimal weight.
- Finite element analysis (FEA): A simulation method to evaluate the behaviour of a structure under loads.
- Optimisation of production parameters: Determining printing parameters, such as infill density and wall thickness, to increase productivity.
- Structural simulation: Computer simulations to check the stability, strength, and durability of structures under real conditions.
- Weight reduction: Optimising the weight of components while maintaining their function and strength.
Industry usage
- Aviation: Optimising aircraft parts to reduce weight and increase strength.
- Automotive industry: Designing lightweight and durable automotive components, such as suspensions and body components.
- Biomedical engineering: Creating optimal implants and medical devices with high durability.
- Construction: Design of lightweight support structures and architectural elements.
- Sports: Optimising the shape and weight of sports equipment to improve its performance.
Importance for the economy
Design optimisation enables companies to design more efficient, lightweight, and durable products, resulting in lower material and manufacturing costs. Through optimisation, companies can bring to market innovative products that excel in functionality and performance. In the automotive, aerospace, and medical industries, where weight minimisation and high strength are key, design optimisation enables the design of more advanced components, which increases competitiveness and innovation.
Related technologies
Mechanism of action
- Design optimisation involves an iterative process of modifying the shape, geometric parameters, and layout of model elements to obtain the best solution. The process begins with defining constraints and optimisation criteria (e.g. minimising weight and maximising strength). The model is then tested using simulation tools, such as FEA, to determine how changing parameters affect its mechanical properties. After each stage of modification, the model is compared with predetermined criteria until an optimal result is obtained.
Advantages
- Reducing production costs: Reduced material consumption due to optimised geometry.
- Increasing strength: Shape optimisation enables maximum mechanical strength with minimal use of raw materials.
- Reducing design time: The automatic generation of different design variants reduces the time needed for the final design.
- Improved performance: Optimised products have a better weight-to-strength ratio.
- Weight minimisation: Reducing the weight of components while maintaining their functionality.
Disadvantages
- Parameter overestimation: Over-optimisation can lead to structural strength problems.
- Simulation errors: Inaccurate simulations can lead to incorrect optimisation results.
- Complexity of analysis: Optimising complex designs can be time-consuming and computationally resource-intensive.
- Tool costs: Advanced design optimisation tools can be expensive.
- Non-compliance with standards: Optimised designs must comply with regulations and safety standards.
Implementation of the technology
Required resources
- Structural analysis software: Mechanical simulation tools, such as ANSYS, Abaqus, and SolidWorks Simulation.
- Powerful computers: Equipment to support large simulations and numerical analysis.
- Mechanical engineers: Specialists in design, structural analysis, and structural optimisation.
- Version management systems: Tools for monitoring and documenting changes in designs.
- Material libraries: Data on mechanical properties of materials used in designs.
Required competences
- Knowledge of optimisation methods: Ability to apply optimisation algorithms and simulations.
- Computer simulation: Ability to perform simulations and structural analysis.
- 3D model creation: Knowledge of CAD model design and editing techniques.
- Strength analysis: Ability to assess the strength and mechanical stability of designed components.
- Project data management: Ability to manage versions and monitor changes in designs.
Environmental aspects
- Energy consumption: High demand for computing power when performing simulations.
- Raw material consumption: Reducing the amount of material used in production while maintaining product quality.
- Waste generated: Design optimisation can reduce production waste.
- Recycling: Design with future material recycling in mind.
- Emissions of pollutants: Emissions from the operation of computers and design optimisation equipment.
Legal conditions
- Construction safety standards: Safety and mechanical strength requirements of the designed elements.
- Intellectual property protection regulations: Copyright protection for optimised designs and 3D models.
- Certification of materials: Requirements for compliance of materials used in projects with technical standards and norms.
- Industry standards: Design optimisation requirements for specific sectors, including aerospace, automotive, and medical, such as ASME and ISO standards.
- Regulations for recycling and sustainable design: Standards and regulations for green design and the recyclability of the materials used.