Methodology for transferring topology optimization results into a production- and lightweight-oriented differential design

Deriving parametric CAD geometries from topology optimization results is a time-consuming step in the development of lightweight components, as the topology developed for the given building space corresponds to a non-parametric integral model. A labor-intensive constructive geometry repatriation is necessary and the choice of usable manufacturing processes is limited due to the integral design. Depending on the quantity, the components are often cast or additively manufactured. These restrictions prevent the economic use of topology optimization. Against this background, a methodology was developed with which topology-optimized structures can be converted into a production- and lightweight-oriented differential design for any quantities. The applicability and added value of the methodology are validated by successfully applying it to a mechanical engineering component.