Optimization of Lightweight Components through Hybrid Topology Optimization and Generative Design in Additive Manufacturing

Generative design (GD) and topology optimization (TO) are two advanced methods that make it possible to design lightweight and high-performance structures for industrial and mechanical needs. This study offers an approach that combines generative design and topology optimization to reach the best possible balance of material efficiency and manufacturability in complex components. By utilizing GD's capacity to provide several design options within predetermined parameters and TO's material distribution methodology, the suggested approach minimizes weight while maximizing structural integrity. To validate the methodology, a case study involving optimization of performance, weight, and manufacturability of a motorcycle triple clamp is discussed in the paper. The study uses ANSYS for TO to create a preliminary efficient design, it then uses Fusion 360's Generative Design tools to develop the design and investigate various manufacturable configurations (additive and subtractive manufacturing). The final design is confirmed by finite element analysis (FEA), which evaluates each alternative's mechanical performance, manufacturability, with significant weight reduction—up to 35%—while preserving manufacturing viability and structural integrity.