Mechanical performance of generative design structures for material extrusion: solid vs shells across mass targets

This study compares solid and shell generatively designed PLA components for material extrusion (MEX) at matched mass targets (100, 150, 200 g). Geometries were generated Generative Design (GD) and manufactured by MEX, then tested in a 30° quasi-static compression rig representing prosthetic heel strike. Solid designs achieved up to 92% higher peak load, but failed abruptly, whereas shells exhibited lower strength but progressive, energy-dissipating failure. Results show that simple shelling of GD outcomes cannot replace iterative GD refinement for weight-critical, load-bearing parts.