These slides were presented at the NAFEMS World Congress 2025, held in Salzburg, Austria from May 19–22, 2025.

Abstract

This paper investigates the concept of generative design, focusing on the integration of finite element models and topology optimization techniques to achieve optimal structural performance under specific constraints. The study emphasizes the dual objectives of adhering to weight restrictions and maximizing stiffness in the design of lightweight structures. Importantly, the generative design process can originate from either a CAD model or a finite element model, providing flexibility in design development. By employing FEM, engineers can accurately assess structural behaviour under various loading conditions, informing the optimization process. The study also incorporates critical constraints, including global stress limits and load factors derived from linear buckling analysis, to ensure structural integrity. The application of user-friendly wizards further supports the engineer throughout the design process, guiding them in setting parameters and constraints effectively. Herein, topology optimization plays a pivotal role, enabling the creation of innovative designs that satisfy stringent weight criteria while ensuring maximum rigidity. PERMAS is used to solve the topology optimization problems, whereas optimization-relevant data is generated in VisPER via the so-called TopoWizard. The methodology is demonstrated using selected examples from the literature. The result of the topology optimisation is a filling ratio distribution within the design space. A clear solid/void distribution is required to interpret the results. Using the Design Wizard, the hull of the optimized design space can be smoothed, a quad layout generated, CAD-compatible splines fitted and exported as a step file. Furthermore, quadrilateral layouts on surfaces are essential for defining quadrilateral meshes, for fitting splines for engineering design and analysis. Additionally, the paper discusses the significance of the STEP file format for CAD export, enhancing interoperability and collaboration among design teams compared to the previously used .stl format. Through detailed case studies, this research also illustrates how these methodologies can streamline the product development process, leading to advanced structural solutions that balance performance, weight efficiency, and manufacturability. The findings highlight the transformative impact of generative design on modern engineering practices, enabling the creation of high-performance components tailored to specific application requirements. This significantly reduces development times in the product creation process and avoids 'œmanual' optimization steps due to the otherwise usual large number of CAD variants at the start of a new project. [1] Hongyuan Ren , Bo Xia, Wenrui Wang, Xueqian Chen, Yang Liu, Pingzhang Zhou, Jianbin Du: 'œAMRTO: Automated CAD model reconstruction of topology optimization result', Computer Methods in Applied Mechanics and Engineering 435 (2025) 117673, https://doi.org/10.1016/j.cma.2024.117673 [2] Kendrick M. Shepherd, Rene R. Hiemstra, Thomas J.R. Hughes: 'œThe quad layout immersion: A mathematically equivalent representation of a surface quadrilateral layout', Computer Methods in Applied Mechanics and Engineering, Volume 417, Part B, 15 December (2023), 116445 https://doi.org/10.1016/j.cma.2023.116445 [3] Zhi Li, Ting-Uei Lee, Yi Min Xie: 'œInteractive 3D structural design in virtual reality using preference-based topology optimization', Computer-Aided Design, Vol. 180 (2025), https://doi.org/10.1016/j.cad.2024.103826