Optimum design of automobile components using lattice structures for additive manufacturing

Abstract In today’s world, reducing fuel consumption is one of the most important goals for the automotive industry. For this reason, weight reduction is one of the main topics in this research and for various companies. In this research, topology optimization was conducted on a suspension arm as a means of ensuring balance in automobiles. Subsequently, the model, formed by topology optimization was filled with a lattice structure and re-optimized by size optimization to obtain optimum dimensions for the model. These operations are described as lattice structure optimization. Additive manufacturing (3D printer) is necessary to produce complex models (after topology and lattice structure optimization). A static analysis of the new models was conducted by using the finite element method, and the results were compared with those of the initial design of the model. As a result of the comparison, positive results were obtained, and it was shown that topology optimization and lattice structural optimization could be used in the design of vehicle elements. According to the results obtained from lattice structure optimization, design structure can be formed more reliably than via topology optimization. In addition, both configurations and layouts of the cellular structures have a special effect on the overall performance of the lattice structure.