Optimization of Metallic Support Geometry for Automotive Doors Using CAD, CAE, and Taguchi Method to Improve Structural Rigidity

The structural performance of automotive doors is highly dependent on their metallic support; however, conventional development processes often involve multiple CAD-CAE iterations, which increase lead time and engineering effort. This study presents a methodology for optimizing metallic support geometry by integrating Computer-Aided Design (CAD), Computer-Aided Engineering (CAE), and the Taguchi Design of Experiments (DOE). A Taguchi L16 orthogonal array was used to evaluate eight key geometric factors, including material thickness, fixation point configuration, and geometric reinforcements. Finite element simulations with a meshless solver significantly reduced pre-processing time without compromising accuracy. By analyzing the signal-to-noise (S/N) ratio, the optimal factor combination was identified, which maximized stiffness while minimizing displacement and ensuring robustness against material variability. The optimal design achieved a stiffness of 248 N/mm, a substantial increase over the baseline’s 39 N/mm. This design demonstrates the potential of this methodology to dramatically improve structural performance from the early stages of development and accelerate product development by reducing design iterations.