Topology optimisation is a mathematical method used at the concept level of design development. The aim of this method is to spread the amount of material present more effectively over the model. It takes into account the boundaries set by the designer, applied load, and space limitations to create a design.
In simple terms, topology optimisation takes a 3D model and creates a design space. It then removes or displaces material within it to make the design more efficient. While carrying out the material distribution, the objective function does not take aesthetics or the ease of manufacturing into account.
At the very least, the method needs us to provide the magnitude of loading and the constraints within which it should operate. Using this information, the optimisation algorithm creates a possible load path using the minimum amount of material.
Once a design is finalised, we use additive (and sometimes subtractive) manufacturing methods to produce the part. As the name suggests, in additive manufacturing (here on out referred to as AM), the material is added (e.g. 3D printing) bit by bit until the final model is complete.
AM is capable of creating complex shapes and structures that may be extremely difficult to create using other methods. This is why we prefer it for creating complex products that emerge after optimisation.
Sometimes, however, the design suggested by topology optimisation is too complex even for AM. In such situations, we make small changes to the design to improve its manufacturability.
Andreas Velling
