Additive Manufacturing and Topology Optimisation in Gearbox Design
Overview
BEng Mechanical Engineering final year dissertation optimising a knee powered orthosis gearbox using topology optimisation and additive manufacturing. The project demonstrates how intelligent infill strategies in 3D-printed components can reduce weight by 25.2% while maintaining structural performance.
Key Achievement: Integrated MATLAB + Abaqus FEM workflow to characterise gyroid lattice properties and deliver a lightweight, manufacturable design.
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Research Summary
Objective: Reduce weight and improve stiffness in knee powered orthosis gearboxes through topology optimisation and variable-density infill strategies.
Methodology:
- Automated MATLAB + Abaqus workflow for generating and simulating lattice structures
- Characterised gyroid triply periodic minimal surfaces (TPMS) across multiple infill densities
- Compared iterative FEM approach with nTopology homogenisation for validation
- Designed and 3D-printed optimised gearbox components
Results:
- 25.2% weight reduction compared to baseline geometry
- Stiffness maintained through variable-density infill optimisation
- Validated prototypes printed successfully with acceptable dimensional tolerances
Key Skills Demonstrated
- FEA & Optimisation: Abaqus FEM, topology optimisation, lattice characterisation
- Automation: MATLAB procedural geometry generation, batch FEM processing
- CAD/Manufacturing: 3D printing design, DfM principles, tolerancing
- Analysis: Regression modelling, sensitivity studies, material homogenisation
- Technical Communication: Comprehensive report writing with visualisations