Topology Optimization Using the SIMP Method for Significant Structural Mass Reduction

Abstract

In the design of high-performance structures, Total mass remains the key constraint on design success. Every gram saved improves flying duration, payload capacity, and operating efficiency. This study addresses the inherent limitations of traditional “trial-and-error” design methodologies, which often rely on engineer intuition and result in structurally inefficient components. To overcome these challenges, this research applies a density-based topology optimization framework to a critical load-bearing bulkhead. By leveraging the Solid Isotropic Material with Penalization (SIMP) method, the component’s material distribution was mathematically refined to align strictly with its primary load paths. This computational method makes it possible to strategically get rid of "dead weight" while strengthening areas of high stress. The optimization that came out of it led to a 50% decrease in total mass compared to the baseline design. This made the part more efficient in terms of load carrying. To make sure the optimized geometry is safe for flight, Finite Element Analysis (FEA) was used to test it. This showed that the leaner structure keeps its mechanical integrity and safety margins even when it is under the most stress. These results show that adding topology optimization to the early design phase is a repeatable, high-impact way to make the next generation of weight-sensitive aerospace structures. This work offers a scalable solution for enhancing structural performance and mission versatility by shifting from intuitive geometry to mathematically derived forms, all while maintaining structural safety.