Scaling Generative Design for Production Through the Use of Standard Parts
Generative Design (GD) tools can produce high-performing components with complex geometries that are challenging to conceive via traditional methods. While potentially disruptive, GD tools have yet to achieve widespread use in industry. One reason is that current GD tools are limited to manufacturing methods capable of producing intricate geometries that GD often creates such as 3D printing. To overcome this barrier, this paper quantifies the benefit of altering generatively designed parts to use standardized elements like wire stock and sheet metal via processes such as CNC bending and water jet cutting. Using a parametric cost model, we show that parts incorporating standard components can halve the unit price for production volumes of only 4 parts. Finite Element Analysis (FEA) reveals that replacing up to 60% of part volume has minimal impact on performance. Our findings highlight a gap and opportunity in existing GD research.