Topology Optimization and Additive Manufacturing: A Convergence Study Between MATLAB and Altair's Industrial Application

Topology optimization is an efficient tool in structural and product engineering, enabling the design of efficient, cost-effective, and high-performance components. Therefore, this study presents a topology optimization-enhanced redesign process for industrial components of an additively manufactured 3D handbrake instrument and subsequent its structural evaluation using Finite Element Analysis (FEA). Hence, the aim is to enhance structural performance and manufacturing adaptability in a competitive industrial context specifically by reducing production time and material consumption for a brake lever bar and its base support. In this path, optimization was conducted using both commercial software Altair and standard MATLAB implementation. The methodology involved defining and optimizing the initial models with each approach, converting the results into three-dimensional CAD models, and subsequently evaluating their mechanical performance via numerical simulations in FEA/CAE software (ANSYS). Finally, the designs were sent for additive manufacturing by Fused Filament Fabrication (FFF). The results demonstrate the potential of topology optimization in improving structural efficiency while addressing manufacturing requirements.