Current Status of Research on Lightweight Design and Manufacturing of Robot Joint Modules Based on Topology Optimization

The lightweight design of robotic joint modules is a key breakthrough in improving motion performance. The core challenge lies in the fact that traditional manufacturing processes (casting/milling) cannot achieve the theoretically optimal topological optimization structure, resulting in persistent issues such as high joint inertia, slow response speeds, and high energy consumption. 3D printing technology, through its layer-by-layer manufacturing process, can overcome geometric constraints, making the engineering application of complex topological and lattice structures possible, thereby providing an irreplaceable solution for joint lightweighting. This paper reviews the current state of research on lightweight design and manufacturing of robotic joint modules based on topology optimization, with a focus on the design and manufacturing collaboration of robotic joints through topology optimization. Through this study, it was found that the collaborative application of topology optimization technology with 3D printing, CNC machining, and other processes has already achieved weight reduction in joint modules across industries such as industrial, medical, and humanoid robotics, while simultaneously enhancing stiffness and heat dissipation performance, providing diverse technical pathways for the high-performance development of robotic joint modules.