Development of a CAD–FEA Integrated Automation Add-In for DfAM-Aware Topology Optimization: A Case Study on an Additively Manufactured Pusher Duct Support Bracket for a Novel UAV Prototype Article Swipe
H. Kursat Celik
,
Ali Elham
,
Recep Çınar
,
M. Ali Erbil
,
Robert Entwistle
,
Allan E.W. RENNIE
,
Ibrahim Akinci
·
YOU?
·
· 2025
· Open Access
·
· DOI: https://doi.org/10.3390/app152212341
YOU?
·
· 2025
· Open Access
·
· DOI: https://doi.org/10.3390/app152212341
The integration of additive manufacturing (AM) and topology optimization (TO) is transforming mechanical design and prototyping practices across multiple engineering sectors, including agricultural and aerospace applications. This study presents the development of TODfAM, a bespoke SOLIDWORKS add-in that automates TO workflows and embeds Design for Additive Manufacturing (DfAM) principles directly within a parametric CAD environment. The tool integrates parametric modelling, finite element analysis (FEA)-based structural evaluation, and TO in a unified platform, enabling automated generation and assessment of design iterations with respect to both mechanical performance and AM-specific manufacturability constraints. A case study on a pusher-duct support bracket for an Unmanned Aerial Vehicle (UAV) was conducted to demonstrate the functionality of the developed workflow. The optimized bracket achieved a 13.77% mass reduction while maintaining structural integrity under representative loading conditions. The CAD-integrated framework reduces toolchain hand-offs and allows early manufacturability evaluation within the design environment, thereby improving workflow continuity and consistency. The principal novelty of this work lies in the establishment of a fully CAD-native, DfAM-aware optimization framework that consolidates the design-to-manufacturing process into a single automated environment. This approach not only streamlines pre- and post-processing tasks but also promotes wider industrial adoption of AM by providing a practical, designer-oriented route to lightweight and manufacturable structures.
Related Topics
Concepts
Design for manufacturability
Workflow
Toolchain
Parametric design
Topology optimization
Automation
CAD
Aerospace
Engineering
Computer science
Process (computing)
Engineering design process
Integrated design
Finite element method
Design process
Modular design
Parametric statistics
Bespoke
Systems engineering
Engineering drawing
Rapid prototyping
Modular programming
Electronic design automation
Manufacturing engineering
Interconnectivity
Embedded system
Reduction (mathematics)
Computer Aided Design
Process integration
Secondary development
Virtual prototyping
Mechanical engineering
Development (topology)
3D printing
Process design
Design flow
3D modeling
Workcell
Topology (electrical circuits)
Metadata
- Type
- article
- Language
- en
- Landing Page
- https://doi.org/10.3390/app152212341
- OA Status
- gold
- References
- 63
- OpenAlex ID
- https://openalex.org/W7106224266
All OpenAlex metadata
Raw OpenAlex JSON
- OpenAlex ID
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https://openalex.org/W7106224266Canonical identifier for this work in OpenAlex
- DOI
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https://doi.org/10.3390/app152212341Digital Object Identifier
- Title
-
Development of a CAD–FEA Integrated Automation Add-In for DfAM-Aware Topology Optimization: A Case Study on an Additively Manufactured Pusher Duct Support Bracket for a Novel UAV PrototypeWork title
- Type
-
articleOpenAlex work type
- Language
-
enPrimary language
- Publication year
-
2025Year of publication
- Publication date
-
2025-11-20Full publication date if available
- Authors
-
H. Kursat Celik, Ali Elham, Recep Çınar, M. Ali Erbil, Robert Entwistle, Allan E.W. RENNIE, Ibrahim AkinciList of authors in order
- Landing page
-
https://doi.org/10.3390/app152212341Publisher landing page
- Open access
-
YesWhether a free full text is available
- OA status
-
goldOpen access status per OpenAlex
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https://doi.org/10.3390/app152212341Direct OA link when available
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Design for manufacturability, Workflow, Toolchain, Parametric design, Topology optimization, Automation, CAD, Aerospace, Engineering, Computer science, Process (computing), Engineering design process, Integrated design, Finite element method, Design process, Modular design, Parametric statistics, Bespoke, Systems engineering, Engineering drawing, Rapid prototyping, Modular programming, Electronic design automation, Manufacturing engineering, Interconnectivity, Embedded system, Reduction (mathematics), Computer Aided Design, Process integration, Secondary development, Virtual prototyping, Mechanical engineering, Development (topology), 3D printing, Process design, Design flow, 3D modeling, Workcell, Topology (electrical circuits)Top concepts (fields/topics) attached by OpenAlex
- Cited by
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0Total citation count in OpenAlex
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