CAD/CAE Workflow for the Topology Optimization and Geometric Reconstruction of a Structural Component

Abstract

This paper presents a study on the topological optimization of a structural component and the conversion of the optimized result into a manufacturable geometric model. The initial model was developed in a CAD environment and imported into the finite element analysis software, where boundary conditions and loading constraints were applied. The optimization process aimed to minimize structural compliance while reducing material usage and maintaining adequate stiffness. Different volume fractions and design parameters were investigated to identify a suitable optimized configuration. The obtained topology optimization results were analysed in terms of structural continuity, manufacturability, and clarity of the load-bearing features. Since the raw optimized geometry often contains irregular surfaces and complex shapes that are difficult to manufacture directly, the result was further reconstructed using NURBS and PolyNURBS modelling techniques. This stage allowed the creation of a smoother, continuous, and closed geometric model suitable for further analysis and production. Lattice structures are also integrated inside the reconstructed model to reduce mass while maintaining mechanical performance. The proposed workflow shows how CAD/CAE tools can transform an optimized conceptual design into a manufacturable structural component. The results emphasize the importance of post-processing, geometric reconstruction, and manufacturability checks in topology optimization.