A

Seminar

On

Generative Design vs Topology Optimization

Submitted By
Tejal Mahendra Janbandhu
(BE17F02F026)

In partial full-fillment for the award of

Bachelor of Engineering
(MECHANICAL)

Under Guidance of

Prof. M.S. Harne

Department of Mechanical Engineering,

Government College of Engineering, Aurangabad

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 Year: 2020-2021

CERTIFICATE

This is to certify that, the seminar “GENERATIVE

DESIGN VS TOPOLOGY OPTIMIZATION” submitted by
Tejal Mahendra Janbandhu (BE17F02F026) is a bonafide
work completed under my supervision and guidance in partial
fulfillment for degree of Bachelor of Engineering (Mechanical) of
Government College of Engineering, Aurangabad.

Place: Aurangabad

Date:

Prof. M.S. Harne Dr. S.B. Chikalthankar

Guide Head of Mechanical Engg. Department

Principal
Government College of Engineering, Aurangabad

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 ABSTRACT

Nowadays, a large number of different tools that support early

phases of design are available to engineers. In the past decade a specialized set
of CAD-based tools were developed, that support the ideation process by
generating different design alternatives according to the criteria given by the
designer, however restricts us to known geometries and encourages the re-usage
of previously designed objects, resulting in robust but nowhere near optimum
designs.

Generative design and topology optimization promise to close this

chasm by introducing evolutionary algorithms and optimization on various
target dimensions. The design is optimized using either 'gradient-based'
programming techniques, for example the optimality criteria algorithm and the
method of moving asymptotes, or 'non gradient-based' such as genetic
algorithms SIMP and BESO.

Thus, this paper focuses on giving an overview over the current

principles and approaches of two types of tools that are Topology Optimization
and Generative Design tools. To investigate to what extent these tools are
suitable for use in early design phases and what are the main differences
between them using a case study .

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 INDEX
Contents Page No.

CERTIFICATE………………………………………………….2
ABSTRACT……………………………………………………..4
1.INTRODUCTION..…...………………….................................7
2.TOPOLOGY OPTIMIZATION….……………………………8
3.METHODOLOGY………….……………………………9
4.ADVANTAGES OF TOPOLOGY
OPTIMIZATION………………………… ………………11
5.APPLICATIONS OF TOPOLOGY
OPTIMIZATION………………………………………………12
6.GENERATIVE DESIGN..…………………………………...13
7.METHODOLOGY……………………………………..14
8.ADVANTAGES OF GENERATIVE
DESIGN…………………………………………………..16
9.APPLICATION OF GENERATIVE DESI...………………..16
10.COMPARISON…………………………………………….19
11.CASE STUDY.……………………………………………..20
12.CONCLUSIONS……………………………………………24
13.REFERENCES….…………………………………………..25
ACKNOWLEDGEMENT……………………………………...26

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List of Figures:
Figure1: Shape Optimization of a Wheel Hub………………………………………….7
Figure 2: Classic Aircraft Nose Fuselages ……………………………………………11

Figure 3 : Topology Ideation 1 ……………………………………………………….11

Figure 4 : Topology Ideation 2 …………………………………………………………11

Figure 5 : Process of Topology on a Bracket…………………………………………12

Figure 6: Before and After images of Generative Design…………………………...12
Figure 7: Casted Wheel Rim …………………………………………………………..15
Figure 8 : Fully Manufactured Wheel Rim ……………………………………………15
Figure 9 : External Side Mirror Mounts……………………………………………….16
Figure 10: Bench Stand ………………………………………………………………..16
Figure 11: Forces acting on the rocker (left) and the suspension assembly model
(right) ….................................................................................................................18
Figure 12: Topology optimization workflow…………………………………………..18
Figure 13 : Optimisation result as a) critical load path and b) mesh body………..19
Figure 14: Final redesigned part geometry (left) and stress analysis (right)……..19
Figure 15 : Results of a generative design study……………………………………20
Figure 16. Design areas with small thickness……………………………………….20
Figure 17. Generative design solution evaluation: design alternatives mapped in the
design (left) space, stress analysis of selected design (right) ……………………20

List of Tables:
Table 1 : the software that offer Topology Optimization…………………………..10
Table 2 : . Comparison ……………………………………………………………….17
Table 3 Comparison of study parameters and results…...…………………………..20
Table 4. Requirements and parameters for topology optimization and generative
design tools …………………………………………………………………………….20

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INTRODUCTION:

Conceptual design is a fuzzy front-end phase of the product

development process in which engineers and designers are generating and
evaluating multiple design alternatives in order to find the most optimal
solutions. Decisions made in this stage will have a strong impact on all the
following product development phases which involve different areas such as
manufacturing, production, testing and finance. Therefore, in the design phase
multiple requirements have to be considered to prevent accumulation of
additional costs in later development phases.
In order to provide support to creativity, to enable faster generation
and testing of the concepts and to speed up the process, engineers have
developed various design tools. Recent advancements in technology, especially
in the field of computing power, machine learning and related algorithms and
additive manufacturing have set grounds to the development of intelligent
design automation tools.
Additionally, new materials are being engineered, which have better
properties and are compatible with the new manufacturing methods. We are
experiencing a gradual shift of design support systems to conceptual design.
Aim of this work is to explore the capabilities of topology
optimization and generative design tools and to define the advantages,
drawbacks and differences between them in order to conclude which tools
would be more suitable for use in the conceptual design phase. To test the
capabilities of the tools, a design study was conducted on a race car suspension
component (a rocker).
Based on their capability to generate multiple optimal design
alternatives by simultaneously considering different material and manufacturing
options, we argue that generative design tools might provide a better support in
early design phases.

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 1. TOPOLOGY OPTIMIZATION :

Figure1: Shape Optimization of a Wheel Hub

Topology optimization (TO) is a mathematical method that

optimizes material layout within a given design space, for a given set of
loads, boundary conditions and constraints with the goal of maximizing the
performance of the system. In essence, topology optimization takes a model of a
part and removes bits from it until the part has less weight and material for
given loading conditions . For example, the goal could be to find the stiffest
possible design using the least material.
The conventional (TO) formulation uses a finite element
method (FEM) to evaluate the design performance. Currently, engineers mostly
use TO at the concept level of a design process as one of the key benefits of
topology optimization is its ability to cut excess weight out of a design. Thus,
the aerospace and automotive industries frequently use this software during
design.

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 2. METHODOLOGY
A. Initial Design:
Topology optimization process starts after the designer has completed an
initial design that full-fills all the functional requirements. This design serves as
the base for the optimization process.

B. Loads and Constraints:

Topology Optimization also requires boundary conditions and
constraints. The design space is existing design body which is being optimized.
User has to define the design space where the optimization algorithm is permitted
to remove material. Next, the loading conditions and fixed points need to be
specified according to the part functionality. After that, material has to be
mentioned for Topology Optimization. This process can be repeated for different
materials, loads, and constraints.

C. Meshing:
In this step, the design body is converted to mesh. User defines different
meshing parameters such as type of element, quality of mesh (coarse or fine), size
of elements, etc. The finer meshing generates more accurate results however it
takes longer to complete the simulation.

D. Optimization Parameters:
Next, the optimization parameters for the part needs to be defined.
Generally, you can choose between following parameters.

• Stress/Factor of Safety (FOS): You can specify maximum stress or

minimum factor of safety based on your design specification.
• Target Weight: If you already have a set target weight for your product,
you can specify in this step. The optimization process will stop once the
target weight is achieved. It is not an ideal option in situations where you

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 want to maximize reduction in weight. If target weight specified for
Topology Optimization is too low, study will most likely fail.
• Number of Runs & Convergence: You can set the number of runs if you
want the optimization process to complete in a stipulated time. The trade-
off here is results may not be most optimal. Another option is to select
convergence criteria, wherein the optimization process will complete if the
change in weight between two sequential simulation iteration is less than
convergence criteria. A general method can be to define maximum
allowable stress or minimum factor of safety along with convergence
criteria. However, the time taken for these criteria is unpredictable and may
take too long to complete. If that happens, alternate approach could be user
can set target weight with number of runs and convergence criteria to
complete the process quicker.

E. Manufacturing Method:
With recent developments in software, topology optimization can be
performed with manufacturing methods as constraints. The general
manufacturing methods available are casting, injection moulding, 3 axis, 5 axis,
and 3D printing.

F. Final Output:
After completing stepsA to E, you can run the study to get the topology
optimized part. It is advisable to run a FEA simulation on the optimized part to
ensure induced stress and deflections are within specification limits.

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 CAD CAE
Catia Inspire by Altair
SolidWorks Ansys
NX COMSOL
Solid Edge Abaqus Topology Optimization Module
Creo (ATOM)
Inventor nTopology
Fusion 360 (Cloud Based only) SIMRIGHT (Cloud Based only)

Table 1 : the software that offer Topology Optimization:

CAE software is generally used for more specialized and critical applications
because it allows a lot more control over meshing, loads, material properties, etc.
The trade-off is increased time in training, high software cost and difficulty to
make changes in initial design in the CAE software.

3. ADVANTAGES OF TOPOLOGY
OPTIMIZATION:
• It reduces weight while limiting stress or FOS.
• It improves stress distribution.

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 4. APPLICATIONS OF TOPOLOGY
OPTIMIZATION :

A. In Aircraft Industry:
Aircraft nose fuselages are classically sized and strengthen thanks to horizontal
and vertical stiffeners.

Figure 2: Classic Aircraft Nose Fuselages

Several topological optimizations on Nose Fuselage propose innovative design

principles, first by demonstrating that the direction of the stiffeners, not
automatically in vertical or horizontal direction, but rather angled, is key
parameter, and secondly by consequence, showing that all the horizontal and
vertical stiffeners are not all necessary. This example illustrates numerical
simulation as way of weight breakdown optimization directly impacting
Aircraft Performances.

Figure 3 : Topology Ideation 1 Figure 4 : Topology Ideation 2

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 B. In Brackets:

Figure 5 : Process of Topology on a Bracket

5. GENERATIVE DESIGN :

Figure 6: Before and After images of Generative Design

It doesn’t refer to a specific algorithmic process rather we grow or

add part where there is more stress like bones have more density in regions
where there is more stress .Rather than removing material as in Topology
Optimization we change the Shape, Density and Orientation in the lattice
structure of material to meet the loading criteria.
Most generative design methods are inspired by natural selection and
many such methods are also known as genetic algorithms, The reason for
generative design’s recent rise is Additive Manufacturing. The most well-
known and useful advantage of generative design today is for light-weighting
parts, which it does staggeringly well. In some cases, generative design can
offer mass reductions of up to 70 percent.

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 The major difference is that it “generates” several design options based
on input constraints such as material, function, weight, and cost.
The process combined with the power of digital computers that can
explore a very large number of possible permutations of a solution enables
designers to generate and test brand new options, beyond what a human alone
could accomplish, to arrive at a most effective and optimized design. It mimics
nature’s evolutionary approach to design through geneticvariation and selection.

6. METHODOLOGY
A. Interface Geometry
This step involves defining all the mating or connecting parts. This works
as a base for your generative design study and helps it understand how your
generative design will be connected to the rest of the design.

B. Geometry to Preserve and Obstacles

In this step, those design features are defined which should not change
during the design process. These may include standard geometries such as holes
for fastening, cut-outs, projections for locating, etc. Next, the user also needs to
define external geometries present in the assembly which will prevent the
software to add material in those regions (obstacles). This step depends on a
particular application and its optional.

C. Loads and Constraints

As generative design is a simulation process, it needs loads and
constraints on the geometry per the design specification similar to how it is
done in finite element analysis (FEA).
D. Design Criteria
In this step, design criteria are generally defined using the below attributes:

• Stress: You can specify the maximum permissible stress allowed to be

induced in your generated design.

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 • Stiffness: It is used to control deflection of part. Higher the stiffness, lower
the deflection and vice versa.
• Factor of Safety (FOS): This ensures that all the generated designs have a
certain minimum FOS. The software may generate designs having higher
FOS than specified.

E. Manufacturing Method
Manufacturing considerations can be specified during this step but the
methods are limited to casting, injection moulding, 3 axis, 5 axis, and 3D printing.
It can be skipped but then generated design might not be possible to manufacture
at all or only by 3D printing.

Some of the Leading Companies offering Generative

Design technology:
• Autodesk -> Fusion 360 (Cloud only)
• Siemens -> NX & Solid Edge
• PTC -> Creo
• Dassault Systèmes -> CATIA-Generative Shape Design
• ParaMatters -> CogniCAD (Cloud Only)
• Desktop Metals -> Live Parts (Cloud Only)
• MSC -> Apex

7.ADVANTAGES OF GENERATIVE
DESIGN:
• It generates lightweight designs.
• It gives you 1000s of options to choose which wouldn’t have been possible
otherwise.

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 • The lead-time of the design cycle reduces drastically because designs are
generated quickly and the designer only has to select and validate the
design.
• It eliminates the bias behaviour designer may have due to his experience
and knowledge in generating a new design.
• With additive manufacturing, lattice structures can be assigned to inside of
the part, which allows the flexibility to change the stiffness in the different
areas of the parts.

7.
APPLICATON OF GENERATIVE DESIGN:

A. Volkswagen Applies Generative Design to Microbus:-

Lighter wheels not only reduce the overall weight of the car, they also reduce
rolling resistance on the tires. The new wheels created are 18 percent lighter
than a standard set and, with the help of the software, overall development time
from design to manufacture was cut from 1.5 years to a few months.

Figure 7: Casted Wheel Rim Figure 8 : Fully Manufactured Wheel Rim

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Generative design was also used on the Microbus project to re-imagine the
external side mirror mounts.

Figure 9 : External Side Mirror Mounts

B. In Carpentry Industry:

Figure 10: Bench Stand

The bench was too big to form in a single cast. So it was designed into six
separate pieces, exchanging models to confirm the best splitting lines. A 3D
puzzle was created, where each piece could insert into the next seamlessly, so
when it was welded there would be no problems with alignment. It creates
lightweight parts with an organic aesthetic that saves time, materials, and costs
during the manufacturing process.

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 8. COMPARISON :
1. How do you begin the process?
o A fully defined CAD Model. (Topology Optimization)
o Hold out areas, loads, constraints, and Manufacturing process
based on the project requirements. (Generative Design)
2. What does the system return to you?
o One outcome (Topology Optimization)
o Multiple outcomes (Generative Design)
3. Is the outcome returned CAD ready, or does it have to be rebuilt?
o A mesh model that must be rebuilt as valid geometry in a CAD
system. (Topology Optimization)
o CAD ready for any CAD System Geometry (Generative Design)
4. Will the “generative design” work with any CAD data both as CAD
data input and the CAD data output (outcomes)?
o Restrictions to CAD data inputs and outputs (Topology
Optimization)
o Work with any data/any CAD system, both input &
output (Generative Design)
5. Can manufacturing methods (Subtractive and Additive) be
considered and added as a constraint?
o No (Topology Optimization)
o Yes (Generative Design)
6. Does the solution automatically provide Costing Insights?
o No (Topology Optimization)
o Yes (Generative Design

Table 2 : . Comparison

Topology Optimization Generative Design

It uses an existing design to optimize It generates new optimized designs by growing
it by removing material the part as per the requirements
It gives you only one output It gives you multiple outputs
It is generally done on cloud but Siemens
It can be done on local computer
offers local solving also.

It can only be used in later phases of It is used in starting phase of the designs and it
design where an initial design is gives valuable feedback to engineers for initial
already set design possibilities

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 9. CASE STUDY:
We have conducted a study on a race car crank bell lever design, which is
commonly known as a rocker. Rocker or Bell Crank Lever is one of the
components that form a race car suspension system, which is in our case
directly influenced by a force from a pushrod that is counterbalanced by a
spring rod and an anti-roll bar.

Figure 11: Forces acting on the rocker (left) and the suspension assembly model (right)

A. Topology Optimization:

Figure 12: Topology optimization workflow

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B. Results:

Figure 13 : Optimisation result as a) critical load path and b) mesh body

Figure 14: Final redesigned part geometry (left) and stress analysis (right)

C. Generative Design:

Figure 15 : Results of a generative design study

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 D. Results:

Figure 16. Design areas with small thickness

Figure 17. Generative design solution evaluation: design alternatives mapped in the design (left)
space, stress analysis of selected design (right)

E, Comparison Tables :-

Table 3 Comparison of study parameters and results

Topology optimization Generative design
Initial geometry

Solid part of a rocker Suspension assembly

Materials Al 7075-T6 Al 7075-T6, AlSi10Mg, Titanium 6Al4V,
Stainless steel AISI 304

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Manufacturing methods Not considered 2-axis cutting, 3-axis milling, additive
manufacturing, unrestricted
Objectives Mass reduction up to 50% Minimize mass, Sf ≥1
Study result 1 optimal design, mesh body >100 designs, 8 diverse groups

Mass reduction 45 % Max. 32%

Duration of a study 2 minutes 2.5 hours
Parallel design comparison Not available within the tool Available, mass and stress comparison
Additional design editing 30 minutes, required Not required in some cases

Table 4. Requirements and parameters for topology optimization and

generative design tools
Initial geometry
Design space definition
Number of materials per study
Design for manufacturing
Study result
Duration of a study
(for equal design tasks)
Parallel design comparison
Additional design editing
Topology optimization Generative design
Solid body of a maximum part Surrounding bodies and/or
volume surfaces (existing assembly or
constructed parts)
Maximum volume and preserved Obstacles and preserved geometry
geometry
1 1 or more
Not included Several manufacturing methods
Single most optimal design Multiple optimal designs
Several minutes Several hours
Not applicable Mass, stress, visual comparison
Required Not required for some cases

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 10. CONCLUSIONS:

Generative design tools have greater potential to better respond to the

needs of conceptual design phase, primarily because they are able to
simultaneously test a larger number of materials and generate multiple design
alternatives, which can save time and support greater creativity. However,
generative design tools are still in development and consideration of a few
larger issues that we mentioned is needed before they become broadly used by
engineers. In the conceptual design phase, topology optimization is a better
choice for optimization of already existing components, whereas generative
design provides more support when design layout and dimensions are not yet
defined. Nevertheless, it is possible to use topology optimization tools to get the
initial idea on how to navigate the design, but current tools will only provide the
designers with a single optimal solution for one study. It is important to outline
that both topology optimization and generative design results will greatly
depend on the design space definition, setup of the loads and constraints, as well
as on the set objectives. Hence, to make use of these methods the designers need
to be skilled in defining a model for optimization to be able to set up the design
studies and evaluate the generated results.

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11. REFERENCES:

• https://improvians.com/blogs/generative-design.html
• https://web.altair.com/generative-design-report-download
• https://www.autodesk.com/products/fusion-360/blog/topology-
optimization-is-not-generative-design/
• https://www.researchgate.net/publication/342112695_EVALUATION
_OF_TOPOLOGY_OPTIMIZATION_AND_GENERATIVE_DESIG
N_TOOLS_AS_SUPPORT_FOR_CONCEPTUAL_DESIGN
• https://www.designnews.com/design-hardware-software/vw-
microbus-gets-revamped-ev-generative-designed-parts
• https://www.autodesk.in/customer-stories/volkswagen-generative-
design
• https://www.additivemanufacturing.media/articles/video-topology-
optimization-versus-generative-design
• https://www.technia.com/blog/why-use-function-driven-generative-
designer-or-topology-optimization/

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 ACKNOWLEDGEMENT

Any achievement, be it scholastic or other, does not depend

solely on the individual efforts but on the guidance, encouragement and
cooperation of intellectuals, elders and friends. A number of personalities,
in their own capacities have helped me in carrying out this seminar work.
I would like to take this opportunity to thank them all.
First of all, I would like to express my hearty gratitude to Dr.P.B.
Murnal, Principal, and Government College of Engineering,
Aurangabad for giving me this opportunity to enrich our knowledge.
I would like to express my hearty gratitude to Dr.S.B.
Chikalthankar, Head of the Department of Mechanical Engineering,
for providing permission and facilities to conduct the seminar in a
systematic way.
I express my sincere gratitude to Prof. M.S. Harne, seminar guide,
Department of Mechanical Engineering for inspiring and sincere
guidance throughout the seminar.

Last but not the least , I wish to thank my parents for financing my
studies in this college as well as for constantly encouraging us to learn and
providing us this opportuninty.

Tejal M. Janbandhu.
(BE17F02F026)

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