Generative Design Optimization Using ANSYS
Discovery Under Human Weight Loading with
Varying Materials and Manufacturability
Considerations.
Aim: To carry out static structural analysis and generative
design on a load-bearing structure subjected to human weights
between 50 and 90 kg, by: Changing four distinct materials and
Examining stiffness, deformation, and stress Mass reduction
comparison Assessing the designs' manufacturing viability.
Design optimization is a process of improving the design to
achieve the best possible performance according to the set of
pre-defined criteria. It has some mathematical formulations to
select the optimal design among the alternatives.
PHASES OF WORK
Problem Definition and Literature Review
For human-weight-bearing components, traditional
design techniques are ineffective and result in
overly complex or less-than-ideal designs.
Particularly when dealing with intricate geometries,
a variety of materials, and manufacturing
limitations, these approaches find it difficult to
completely explore the design space.
Maintaining structural integrity, reducing material
consumption, and ensuring manufacturability all at
once is difficult.
This leads to less creative product solutions, longer
design cycles, and increased material consumption
—a gap that this study seeks to fill with generative
design.
Geometry Creation and CAD Modelling
Develop a detailed 3D CAD model of the cycle
frame and associated structural parts.
Incorporate realistic mounting and boundary
conditions.
Ensure dimensions align with real-world vehicle
specifications.
After the design is generated we can use measure
command for checking mass and volume of the
design.
Finite Element Model Setup
Import the CAD model into an FEA software (e.g.,
ANSYS, STATIC STRUCTURAL, LS-DYNA).
Generate an appropriate mesh with adequate
refinement in critical regions.
Assign material properties and thickness variations
for each design case.
Boundary Conditions and Loading Definition
Fixed support at wheel positions of structure.
Vertical load on top surface simulating human
standing/sitting (50–90 kg).
Linear elastic assumption for all materials.
Factor of safety greater than 2.
Apply vertical load simulating body weight F = m ×
g
Simulation and Analysis Execution
Inspect total deformation and von mises stress
plots
Manufacturability analysis
Volume and mass savings from generative design.
Final recommendation on best material-geometry
combo for performance and production.
Result Evaluation and Post-Processing
Analyse results for key parameters:
Deformation patterns
Maximum stress and strain
Optimization and Recommendation
Identify the most effective material with low stress
induced and less deformation
Propose optimized design based on findings.
Generative design helps in optimizing the best
possible design.
