A comprehensive SIMP-based topology optimization study for structural components: GE Bracket and 3D-printer Adapter applications

A workflow for three-dimensional topology optimization (TO) based on the Solid Isotropic Material with Penalization (SIMP) method is presented in this study. The focus is placed on numerical stability and safety-driven design. The GE Jet Engine Bracket is used as a benchmark to calibrate the solver, and a mesh convergence analysis is conducted to ensure that the optimized shape is not influenced by the mesh size. For this benchmark, a mass reduction of 75.23% is achieved. Structural integrity is assessed according to the FKM Guideline; although localized stress concentrations are found, a static safety factor of 1.43 is obtained, which meets the design requirements. The validated workflow is then applied to the Z-axis adapter of a Bambu Lab A1 Mini 3D printer under static loads. Two design variants are created for different manufacturing methods: the Additive Manufacturing (AM) variant achieves a mass reduction of 15.38% with a safety factor of 1.65, while the CNC machining variant achieves a mass reduction of 14.42% with a safety factor of 1.52. All designs are verified through Finite Element Analysis (FEA) to confirm safety margins. Finally, physical prototypes are produced to prove manufacturability and to validate the transition from simulation to real components. The results confirm that SIMP-based topology optimization, when supported by numerical validation and safety checks, is a reliable design method for industrial and consumer applications. • ANSYS TO workflow validated with GE Jet Engine Bracket benchmark. • Safety confirmed via FKM Guideline (SF 1.43) despite stress peaks. • Z-axis adapter optimized: > 14% mass cut while maintaining stiffness. • Additive and CNC variants developed and verified for manufacturability.