System Level Design Optimization Method for Lightweight Manufacturable Design

Abstract

This paper presents a method for a system level design optimization, using currently available commercial tools. A process outlining the optimization steps to be used was created based on performing topology optimization on important components and performing a conceptual topology optimization on the entire system. Using this process, a study was performed on a ceiling structure provided by an industry partner. From the design requirements, three primary areas were targeted for design optimization, the component level optimization of the cross beam component, the component level optimization of a roof attachment bracket, and the system level of the general roof structure. This study produced a design for the ceiling structure that reduced the total mass of the system by 34%, while also reducing the amount of total components in the system by 30%.