Methodical software-supported, multi-target optimization and redesign of a gear wheel for additive manufacturing

Additive manufacturing gives new freedom to part design by enabling the manufacturing of complex structures. Mastering this degree of freedom poses challenges for product developers with experience from conventional manufacturing. In order to meet this challenge in a structured manner, a practical method is presented in which creative idea development is combined with software-based design optimization. First, optimization goals are defined. Then a baseline design is developed through a creative ideation process. Variants are derived from the baseline design, evaluated according to simulation results and selected. The method is illustrated by the development of a lightweight and function-integrated gear wheel.