Redesign of drivetrain component of a shell eco marathon vehicle for additive manufacturing via topology optimization

Additive Manufacturing (AM) has been an emerging technology and an important alternative to conventional manufacturing methods as it enables production of lighter parts that are potentially more durable. In this context, the design for additive manufacturing (DFAM) has been drawing considerable amount of attention mainly in aerospace, automotive industries as well as in academia. On the other hand, the ability of additive manufacturing to manufacture complex topology often is the outcome from topology optimization, makes topology optimization a good design tool for additive manufacturing. The use of lighter and more durable components is of critical importance in aerospace and automotive industries due to the goals for more efficient use of the energy resources and / or higher performance. The main objective of the present work is to redesign a structural component of the drivetrain of the Shell Eco-Marathon vehicle, SAITEM EVRIM-4, with the use of Altair Inspire™, an industrial generative design tool, by application of Topology Optimization for Additive Manufacturing aiming mass reduction. The results of finite element analysis that have been performed as part of the present work clearly show that the redesigned part is capable of withstanding to applied loads while the part is in operation. Moreover, a significant mass reduction is achieved with the redesigned model.