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 key to accurate Topological Optimisation is the ability to simulate the mechanical performance of the component designs the optimisation software produces. With its unique Digital Twin Simulations Sarginsons is in the unique position of being able to do so, effectively enabling an virtual iterative design process. One which maximises lightweighting.
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 the auspices of 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 but also taking cost out of the manufacturing process.
Sarginsons R&D proposal for £6m in grant funding, 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 form.
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 software, which creates castable components, 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 topologies ability to make larger, lightweight, mechanically strong components in this organic style will mark a seminal moment in design history. Sarginsons is changing the way the world looks and performs.
