Lightweight redesign of a monitor wall mount using FEM-based topology optimization in Altair Inspire.
Goal: cut mass significantly while maintaining structural integrity under defined loads and constraints.
Situation
Conventional wall-mount brackets are often over-designed, driving up weight and cost.
Task
Deliver a lightweight, manufacturable wall-mount that meets stiffness/strength limits with clear, quantified savings.
Action
- Built baseline assembly; defined loads & boundary conditions at assembly and part level.
- Ran topology optimization (objective: mass minimization; constraints: displacement & stress).
- Interpreted iso-topology into manufacturable geometry; verified with FEA (stress/displacement).
- Benchmarked pre/post mass at assembly and component level.
Result
- Assembly: mass reduced 82.58% (8123.92 g → 1415.18 g).
- Arm: mass reduced 65.16% (Al 2024).
- Link: mass reduced 48.92% (Al 2024-T3).
Design meets functional targets with a much better mass-to-stiffness ratio.
Final optimized wall-mount assembly — total mass reduction 82.58%.
Optimized ARM; mass −65.16% with stiffness maintained.
Optimized LINK; mass −48.92% with required load-path continuity.
- 📑 Final Report (PDF):
TopologyOptimization_Report.pdf - 🖥️ Final Presentation (PDF):
TopologyOptimization_Presentation.pdf
- Altair Inspire: topology optimization (mass minimization with displacement/stress bounds).
- FEA validation on optimized geometry (stress & displacement).
- Design interpretation from iso-surface to manufacturable CAD.
To keep the repo lean, CAD is published as a release asset:
👉 Download CAD (STEP/IGES, ZIP):
cad_models.zip
Includes: Link.iges, Model.step, Monitor_Bracket.iges, Wall_Mount.iges
- Demonstrated lightweight engineering with large, verified savings.
- End-to-end CAE workflow: baseline → optimization → FEA → interpreted design.
- Approach is transferable to automotive/aerospace components.
Distributed under the MIT License.