Simultaneous Multi-Material Part and Reinforcement Topology Optimization With Structural Performance Objectives

Within the automotive industry, the demand for lightweight yet structurally sound systems continues to increase, driven by environmental regulations and performance targets. Furthermore, as manufacturers continue to introduce new electric vehicle platforms, overall vehicle energy efficiency is increasingly achieved through weight reduction. In recent decades, topology optimization (TO) has emerged as a leading design tool for generating high-performance structures that satisfy lightweighting requirements through efficient material distribution within a defined design space. In structural design, TO can be leveraged to yield optimal configurations of both a base structure and an applied surface reinforcement material, allowing additional design freedom in the pursuit of stiff, lightweight design solutions. However, conventional TO frameworks are limited in how they couple these two design domains and are not well suited to optimize both simultaneously without compromising solution quality or design autonomy. This work introduces a novel workflow, termed Simultaneous Reinforcement Topology Optimization (SRTO), capable of concurrently optimizing a base structure and its surface reinforcement material while considering overall structural performance. The proposed methodologies use material homogenization techniques to represent reinforcement surface material existence within the base structure’s design space, allowing for seamless coupling between the two domains. The SRTO workflow is verified using academic and industry-level case studies, demonstrating significant performance improvements over existing designs. Optimization results yield designs not otherwise attainable with conventional methods, showing the versatility and capability of SRTO to generate stiff, lightweight structures. Compared to a distinct baseline workflow, SRTO methods see a reduction in the base structure volume while generally maintaining structural performance. Additionally, qualitative improvements made to surface geometry are yielded, highlighting SRTO’s capacity to promote surface reinforcement-driven designs.