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Design Optimization of Automative Bracket for Additive Manufacturing
Ajay Prasad
Ajay Prasad
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Design Optimization of Automative Bracket for Additive Manufacturing

Optimize an automotive bracket using topology optimization and latticing for additive manufacturing.

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Apply now
 ET /
8 weeks, 2-3 hours per week
No experience required
No experience required
Some experience required
Degree and experience required


Lightweighting is strategically decreasing mass while preserving overall strength and structural integrity. Additive manufacturing has created opportunities to apply new lightweighting techniques that enable you to achieve even greater mass reduction.

In today's rapidly evolving engineering landscape, additive manufacturing (AM) stands at the forefront of innovation, offering unparalleled opportunities for maximizing performance and efficiency while minimizing lead times. Companies across industries are embracing AM to push the boundaries of traditional manufacturing methods and unlock new possibilities in design optimization.

In our Build Project, you will learn the power of computational design and AM technologies to lightweight mechanical parts, mirroring the innovative approaches in real-world industry applications. Through this project, you will gain invaluable skills in computational design, material selection, and additive manufacturing, positioning them for success in the dynamic landscape of modern engineering and manufacturing roles.

Session timeline

  • Applications open
    May 27, 2024
  • Application deadline
    June 23, 2024
  • Project start date
    Week of July 8, 2024
    Week of
    July 8, 2024
  • Project end date
    Week of

What you will learn

  • Latticing and Topology Optimization: Develop proficiency in using advanced computational design tools such as nTop for light-weighting. You will gain hands-on experience in topology optimization and lattice structure generation within the software.
  • FEA Simulation: Develop the ability to integrate your knowledge of mechanical principles, including material properties, structural analysis, and load conditions, with computational design techniques. You will apply static structural analysis to validate their computational design results, ensuring that their lightweight designs meet the required structural performance criteria.
  • Parameter Sweep/ Design of Experiments: Learn how parameter optimization and DOE techniques are employed in the automotive industry to select optimal lattice parameters for lightweight design. Through this process, students will develop skills in experimental design, data analysis, and optimization specific to automotive light-weighting applications.
  • Design for Additive Manufacturing: Understand additive manufacturing processes and their implications for lightweight design. You will learn about the capabilities and limitations of additive manufacturing techniques such as selective laser sintering (SLS) or fused deposition modeling (FDM) and how these processes influence design considerations.
  • Project Management: Develop project management and documentation skills. You will learn to plan and organize your workflow, manage project timelines and resources effectively, and document your design iterations, analysis results, and final recommendations in a comprehensive project report.
Build Projects are 8-week experiences that operate on a rolling basis. Selected participants engage in weekly live workshops with a Build Fellow and 2-15 other students.

Project workshops

Introduction to Design for Additive Manufacturing (DfAM) and Implicit Modelling
Shelling and Intro to Latticing
Advanced Latticing Techniques
Static Analysis
DOE for Lattice Parameters
Topology Optimization
Integrating Latticing and Topology Optimization
Finalize and Present the Lightweight Project


  • Computer-Aided Design (CAD): Prior coursework or experience in Computer-Aided Design (CAD) tools such as SolidWorks, Autodesk Fusion, or nTop. Ability to create, modify, and analyze 3D models and assemblies.
  • Fundamental Mechanics: Knowledge from courses such as Statics, Dynamics, and Mechanics of Materials. Familiarity with concepts like force equilibrium, stress, strain, and material properties.
  • Static Structural Analysis: Experience with Finite Element Analysis (FEA) such as Ansys, Abaqus or similar methods to evaluate the structural integrity of designs. Ability to interpret analysis results to make informed design decisions.
  • Report Writing and Presentation Skills: Proficiency in using Microsoft Word or similar software to create detailed project reports. Ability to document design processes, analysis results, and conclusions clearly and concisely.

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About the expert
Ajay Prasad
's Linkedin

Ajay Prasad is employed at a cutting-edge mechanical design software company, contributing to the development of next-generation design tools.With a master's degree in mechanical engineering, Ajay Prasad brings a robust educational background and practical expertise to the table. During their undergraduate studies, he distinguished himself by participating in prestigious international competitions such as NASA Cansat and the European Rover Challenge.With four years of professional experience, Ajay Prasad has developed a comprehensive skill set in mechanical engineering and design.A fun fact: Ajay has tried donuts in every state he has visited in the US.

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