Scaling Generative Design for Production Through the Use of Standard Parts

Generative Design (GD) tools can produce high-performing components with complex, organic geometries – shapes an engineer struggle to draw using Computer Aided Design (CAD). Despite this, CAD use dwarfs GD tool use in industry. One cause is that current GD tools are limited to manufacturing methods, like 3D printing, that can produce intricate geometries. Sometimes, that limitation is unacceptable.

We ask what happens when GD parts are modified to use standard components like wire stock and sheet metal and 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. We propose that research into methods that can translate GD parts to more processes would improve its utility.