Structural Optimization of a Chassis Designed for Metal Additive Manufacturing

ABSTRACT This study investigates the structural optimization of a chassis intended for metal additive manufacturing, focusing on enhancing stiffness‐to‐weight performance while leveraging design freedoms unique to additive manufacturing technologies. Topology optimization and finite element analysis were used to facilitate the design of a custom light weight component of a robot demonstrator. Topology optimization targeted mass reduction, ensuring that compliance and displacement remained within acceptable limits. To assess the influence of material properties on the optimized geometry, simulations were performed using three commonly employed alloys in metal additive manufacturing: Titanium, Stainless Steel, and Cobalt‐Chrome. Finite element analysis was applied to evaluate stress distribution, deformation, and structural efficiency for each material configuration. The comparative FEA results highlight the strong influence of material properties on the structural response of the optimized chassis. Stainless Steel 304 provided enough rigidity but operated closer to its safety limit, while Cobalt‐Chrome showed the highest stiffness and a robust safety margin. Titanium Ti‐6Al‐4V offered the most balanced performance, achieving the highest safety factor and lowest mass, making it the most suitable choice for lightweight, high‐reliability applications in metal AM.