Optimizing Weld Placement in Automotive Structures Using Topology and Multi-Disciplinary Approaches

This work presents two approaches for weld optimization aimed at reducing manufacturing cost and process time, while meeting structural performance requirements in automotive structures. The first approach uses topology optimization to identify the most efficient weld layouts. A design space is generated along mating flanges, joints, and panel interfaces, where potential weld locations are defined. Welds are treated as discrete design variables, and the topology optimization systematically evaluates their contribution to global stiffness and load path integrity. Non-critical welds, those with minimal impact on stiffness, durability, or crashworthiness, are eliminated, resulting in a minimized weld pattern that maintains structural performance. The second approach applies Multi-Disciplinary Optimization (MDO) to balance weld reduction with performance targets across multiple domains, including linear and non-linear stiffness, crashworthiness, and fatigue. Using a preprocessing tool, welds are parameterized to allow flexible control of their placement. A Design of Experiments (DoE) is generated to simulate various weld configurations under relevant load cases. Surrogate models are then developed to approximate the relationship between weld layout and key performance metrics. These response surfaces enable efficient optimization that minimizes weld count while satisfying all structural requirements. Together, these strategies form a data-driven, simulation-based framework for weld design that supports aggressive cost and time reduction targets without compromising safety or durability. The results demonstrate the potential for integrating advanced optimization techniques into early design phases for more efficient and manufacturable vehicle structures.