Integrating manufacturing constraints in existing generative design workflows: wall thickness and cooling channel considerations

Generative Design (GD) offers lightweight, manufacturable solutions, but manufacturing constraints often require indirect handling. Using a deflection lever for Additive Casting, we compare PTC Creo GTO and Altair Inspire using identical load cases and mass-minimisation. Both tools achieved −26% mass and −46% inertia while meeting displacement limits. Wall-thickness control and channel integration show clear trade-offs, yet both tools provide viable designs for early development.