Integrating topology optimization into model-Based systems engineering for lightweight structural design

Abstract Model-Based Systems Engineering (MBSE) is a formalized approach to developing cyber-physical systems (CPS), enabling traceability of system requirements throughout all phases of the product lifecycle. A significant challenge in MBSE lies in the integration of discipline-specific simulations, such as Topology Optimization (TO), into system architectures. TO simulations are essential for optimizing material distribution in structural components (SCs), considering factors such as loads, material properties, and manufacturing constraints. However, defining the initial design space, particularly for complex designs, is an iterative and creative process, complicating its integration into MBSE. This paper proposes a method to seamlessly integrate TO simulations into system architectures by linking specific SC characteristics to the various stages of TO simulation. This integration enhances the reuse of TO models across multiple components and manufacturing processes, such as tailored fiber placement of composites, casting, among others. A case study on the development of SCs demonstrates the effectiveness of this framework, showcasing how integrating TO within MBSE can improve efficiency, reduce complexity, and facilitate the design of lightweight, optimized systems.