Topology Optimisation Workflow in FEA Solvers

Engineering Task

Using topology optimisation to explore efficient structural concepts within a defined design space.

Software Implementation

1. Define the design space — the region where material can be added or removed
2. Define non-design space — interfaces, mounting points, keep-out zones
3. Define the objective — minimise compliance (maximise stiffness) or minimise mass
4. Define constraints — volume fraction, stress, displacement, manufacturing
5. Apply manufacturing constraints — minimum member size, draw direction, symmetry
6. Run the optimisation and review the material distribution

Solver-Specific Notes

• OptiStruct: uses DTPL card for topology design variables; check OPTISTRUCT output for convergence
• Tosca (Abaqus): uses *OPTIMIZATION and *DESIGN DOMAIN cards; review the optimisation history
• ANSYS: Topology Optimisation in Workbench — set Objective, Constraints and Retained Region

Result Interpretation

Topology optimisation produces a concept, not a final design. The result must be interpreted, smoothed, re-meshed and verified with a full analysis.

Common Mistakes

• Not applying manufacturing constraints — produces unmanufacturable organic shapes
• Using only one load case — the optimised design may fail under other cases
• Treating the optimised material distribution as a finished design without re-analysis
• Not preserving load path or interface geometry in the non-design space

Related Knowledge

• Topology Optimisation Review Checklist
• Structural Design Review Checklist