Optimization of Brake Calipers Using Topology Optimization for Additive Manufacturing

The weight optimization of a structure can be conducted by using fewer and downsized components, applying lighter materials in production, removing unwanted material. Topology (TO) is one the most implemented material removal processes. In addition, when it oriented towards additive manufacturing (AM), increases design flexibility. traditional approach compliance optimization, where layout optimized minimizing its overall compliance. However, TO, current state art, mainly used for inspiration not due to complexities lack accuracy solutions. authors, this research paper, explore benefits limitations TO as case study housings front rear brake caliper. calipers were reduction implementing aforementioned procedure. Their topologically optimized, partially redesigned, prepared 3D printing, validated, printed titanium selective laser melting (SLM). reduced 41.6% compared commercial calipers. Designers interested either or automotive engineering exploit findings paper.