A Manufacturable CAD Reconstruction Framework for Topology-Optimized Structures Using Segmentation-Based Geometric Interpretation

Topology optimization has emerged as a powerful computational paradigm for generating lightweight and stiffness-efficient structural configurations; however, the resulting density-based representations remain intrinsically mesh-dependent, geometrically discontinuous, and unsuitable for direct engineering realization or manufacturing integration. This study presents a manufacturable CAD reconstruction and engineering validation framework for systematically transforming topologyoptimized density fields into engineering-ready solid geometries with enhanced geometric controllability and structural fidelity. The proposed methodology employs segmentation-guided geometric interpretation, constrained sectional profile reconstruction, and loft-based CAD modelling to eliminate discretization-induced irregularities while preserving the dominant load-transfer topology identified during optimization. To establish structural reliability, the reconstructed geometries are subjected to finite element reanalysis under identical loading and boundary conditions. The results demonstrate that the proposed framework preserves the global stiffness characteristics and mechanical response of the optimized configurations while significantly improving stress regularity, geometric continuity, and manufacturability. The developed CAD-CAE integrated workflow provides a robust and practical pathway for converting topology-optimized layouts into manufacturable engineering components suitable for downstream design, analysis, and advanced manufacturing applications.