Topology optimization-based lightweight chassis design: A case study on structural efficiency enhancement for an autonomous scale vehicle

This study aims to enhance structural efficiency and achieve material savings by employing the topology optimization method for the lightweight design of an autonomous model vehicle chassis. During the design process, the penalty-based Solid Isotropic Material with Penalization (SIMP) method, available within ANSYS Academic software, was utilized. Initially, a structural analysis of the chassis was conducted, followed by the application of topology optimization based on the finite element method (FEM) results. Through iterative solutions under specified loading conditions and boundary constraints, a mass reduction of approximately 27% was achieved compared to the initial geometry. Despite the reduction in mass, the design maintained its structural integrity. Graphical analyses indicated that the optimization process reached convergence after the fifth iteration, with a stabilized distribution of material. The results demonstrate the potential of topology optimization to develop low-cost, lightweight, yet robust structural solutions, emphasizing its effectiveness as an engineering tool in systems where weight reduction is critical, such as autonomous model vehicles.