Efficient material use by topology optimization integrated with casting simulation

Purpose and goal:

OptCast will develop a new methodology to efficiently combine topology optimization with manufacturing simulation by utilizing a new geometry description technique. The goal is to shorten the development time for cast components and to improve the material utilization.

The optimization technology developed in the project will go from TRL3 to TRL5. Demonstrators will show a reduced lead time for these process steps of 15% together with a reduced material use by 15%. Expected results and effects:

The methodology is expected to provide components that are efficient from a weight and property perspective and will also enable and enhance a sustainable manufacturing method. The early adaptation of the design to casting contributes to reduced scraps in the foundry and improved product life.

The project results are generic and applicable to other manufacturing methods, allowing more product innovations to reach the market faster. In addition to a traditional report, industrial course will also be generated as well as presentations and articles. Approach and implementation:

The project consists of seven work packages that are carried out in collaboration with all participating parties The project core is based on continuous evaluation of the method using both virtual and practical trials. The results will be shown in different demonstrators. The work will be carried out so that both OEMs and SMEs contribute with the required expertise, which means that during the project the results can easily be implement and utilize.

A work package will manage sustainability which ensures that the project contributes to the companies´ and the UN´s sustainability goals.