Automotive Support Components: Generative Design for Subsequent Additive Manufacturing Processes.

Generative design is an iterative design process that involves using AI algorithms to generate numerous design options based on a set of input parameters and design goals. These algorithms explore a wide range of possible design solutions, often using principles inspired by nature or other complex systems. The goal is to create innovative and optimized designs that meet specific performance criteria while also considering constraints such as material usage, manufacturing processes, and cost. On the other hand, topology optimization is a specific technique within the broader field of generative design. It focuses on optimizing the material layout within a given design space to achieve the best structural performance. By iteratively removing material from areas of low stress and redistributing it to areas of high stress, topology optimization can generate lightweight and efficient designs. While topology optimization primarily addresses structural considerations, generative design encompasses a broader range of design objectives, including functional requirements, aesthetic preferences, and manufacturing constraints. This thesis study will introduce a feasible methodology that can be used in industry and actual production; not only for plastic parts but also for Mechanical parts facing severe loads and stresses. The primary objective of this thesis is to leverage Generative Design techniques to enhance the efficiency of redesigning existing components. This entails optimizing material utilization, reducing costs, enhancing mechanical stiffness, and minimizing CO2 emissions. By harnessing Generative Design methodologies, this study seeks to introduce a robust and practical approach applicable within industrial settings and actual production environments. It is pertinent to note that the scope of this research extends beyond conventional applications limited to plastic components, encompassing mechanical parts subjected to substantial loads and stresses. Through this endeavor, a comprehensive framework that integrates design methodologies with real-world engineering challenges has been established, thereby facilitating the transition towards more sustainable and resource-efficient manufacturing practices.