Articles & Research • Optimised Topology, The Mathematics Of Lightweighting
Optimised Topology, The Mathematics of Lightweighting
1st July 2024
Written by Ashley Stafford
Technology
Optimised Topology is the mathematics of lightweighting, which has also been described as the mathematics of a rubber sheet. It is fiendishly complex but it produces inspired designs, seemingly drawn from nature, and quite extraordinary reductions in mass and weight. It should be the essence of every cast component.
The new, organic component designs that topology generates could not be proposed without the ability to simulate mechanical performance and solidification perfectly. Doing otherwise would open the door to product failure and the costs and delays this entails. Because Sarginsons can simulate several iterations of any proposed design, it can always find the perfect design solution, effectively creating a Virtual Rapid Iterative design solution for castings.
Topological Optimisation will change the way tomorrow looks.
Whilst still new technology, Sarginsons has achieved a mass reduction of over 30% on every casting it has applied topology to. And as we push the envelope of our casting technologies, through techniques like 3D core printing and forced cooling, these improvements are only likely to accelerate.
An under appreciated aspect of topology is that it is also useful at finding design solutions to complex issues, such as combining numerous components into one casting. Sarginsons recently merged nine different structures into one large subframe - not only achieving a significant weight reduction (30%+) but also took cost out of the manufacturing process.
Sarginsons R&D recent winning of £6m grant, PIVOT, is all about truly liberating the potential of Topological Optimisation. Rather than repeatedly validating the viability of topological designs through digital twin simulations, the new software PIVOT creates will automatically run simulations to ensure that all proposed solutions are castable and will have the required mechanical characteristics at the correct points across the component form. OEMs just enter the performance they require.
PIVOT will put real casting topology in the hands of OEMs who, being freed from traditional casting constraints, can really push the design envelope in terms of lightweighting, performance and economies. Sarginsons Technology Centre will act as a consultant further enhancing the components created.
Sarginsons believes that access to topological design, which are castable, will change the look, performance and sustainability of tomorrow. It is in the nature of topology to produce organic looking designs which, for the first time, are perfectly complemented by the ability of casting, effectively liquid metal engineering, to take any shape or form.
And topology's ability to make larger, lightweight, mechanically strong components in this organic style will mark a seminal moment in design history. Sarginsons and PIVOT could change the way the world looks and performs.
