Design and Sustainability

Engineered for Sustainability Optimised Performance

Topology Optimisation for Metal Additive Manufacturing

Topology optimisation is a cutting-edge engineering process that refines material distribution within a defined space to meet specific performance goals. By analysing loads, constraints, and design requirements, it identifies areas where material can be removed without compromising strength or functionality. This results in lighter, highly efficient designs that often feature intricate, organic shapes. Traditionally, these complex geometries posed challenges for conventional manufacturing methods. However, advancements in metal additive manufacturing (AM) have made them practical and scalable, enabling innovative solutions for weight reduction, thermal stress management, and structural optimization. Topology optimisation is now a cornerstone of modern engineering, driving progress in industries such as aerospace, automotive, and industrial manufacturing by delivering robust, cost-effective, and high-performance products.

Complexity Without Cost Penalty:

Unlike traditional manufacturing methods, where increased complexity leads to higher costs, AM allows for the fabrication of complex designs with minimal cost impact. In fact, complex designs can sometimes reduce material usage and minimise the need for support structures, further enhancing efficiency.

Optimal Stiffness Design:

Optimal designs often feature fine microstructures and intricate details that are difficult to achieve with traditional methods. Metal AM overcomes these challenges, enabling the realisation of designs with improved mechanical performance.

Design Freedom:

Optimal designs often feature fine microstructures and intricate details that are difficult to achieve with traditional methods. Metal AM overcomes AM eliminates many of the constraints associated with traditional manufacturing. For example, overhangs and cavities that are difficult or impossible to machine can be easily produced with AM, provided that support structures are appropriately managed.

There is a misconception that AM is inherently sustainable. At CONIFY, we assist you in making informed decisions that enable you to adopt AM and drive sustainability through Laser Powder Bed Fusion. Our approach involves designing processes and parts that not only meet the technical specifications but also achieve sustainability performance indicators.

In our case studies, we showcase how additive manufacturing (AM) can outperform traditional machining (CNC) by delivering:

1. Buy-to-fly ratio improvement reaching up to 1:1 reducing material waste
2. Weight reduction through topology optimisation, enhancing performance and efficiency.
3. Reduction in carbon emissions
4. Efficient use of 50% recycled materials, supporting circular economy practices, achieving comparable mechanical performance to virgin materials
5. Aligned with the UN Sustainable Development Goals (SDGs):

SDG 8: Decent Work & Economic Growth – fostering skilled jobs in advanced manufacturing.

SDG 9: Industry, Innovation & Infrastructure – enabling resilient, innovative manufacturing ecosystems.

SDG 12: Responsible Consumption & Production – optimising resources, reducing waste.

SDG 13: Climate Action – lowering carbon footprints with innovative processes.

Case Studies-Sustainability & Cost Analysis

Rocker Arm