Employing generative design methods to develop an optimized automotive part

• Generative design applied to a go-kart steering wheel. • 60 % weight reduction using ASA polymer. • Validation through FDM prototype and torque testing. • Demonstrates synergy between design algorithms and additive fabrication. This study investigates the potential of generative design for optimizing the structural and aesthetic characteristics of a sports go-kart steering wheel. The objective was to minimize weight while maintaining stiffness, strength, and dimensional accuracy. Using Autodesk Fusion 360, multiple design variants were generated under defined load cases and manufacturing constraints. ASA polymer was selected as the optimal material for FDM-based 3D printing due to its favorable balance of strength, UV resistance, and processability. The final prototype achieved a 60 % mass reduction with validated mechanical performance, demonstrating the effectiveness of generative design and additive manufacturing in lightweight engineering applications. The experimental validation was primarily focused on assessing the structural strength under the maximum applied steering torque, while stiffness was evaluated as a secondary performance indicator.