Key topics in topology optimization training for engineers

Design of lightweight load-carrying structural parts is becoming increasingly demanding due to ever-tighter requirements on structural weight, performance, and durability. Topology optimization is the most recent and most promising tool supporting the development of such high-performance load-carrying parts – at least in theory. In practical applications, however, engineers are struggling to formulate and run topology optimization tasks in a way that would result in good and actually usable results. For this purpose, the pitfalls met in this process are reviewed and discussed in a systematic way. These mistakes range from deficiencies in FEA model preparation, over uncritical optimization process monitoring and management, to bad practices employed in resulting model finalization. As it turns out, careful FEA model preparation and its corrections based on a feedback information from the ongoing optimization process are keys to success. Keeping this in mind should prevent a superficially (and not precisely enough modeled) support condition or a missed load case, which may otherwise very quickly result in a useless final design.