Optimizing Lightweight Automotive Connecting Rods Through Integrated Reverse Engineering and Lattice-Based Topology Methods

This study introduces an integrated, reverse-engineering-driven framework for optimizing automotive connecting rods under real-world industrial constraints. The geometric characteristics and material composition of a legacy component were experimentally characterized using high-resolution 3D scanning (Artec Spider Studio 16) and spectroscopy. The resulting data were incorporated into the optimization workflow. Computer-aided design tools, including SolidWorks 2022® Premium 2022 × 64 (Dassault Systèmes SolidWorks Corporation, Waltham, MA, USA) and Geomagic Design X 2022 (3D Systems, Rock Hill, SC, USA), captured precise geometry, while spectroscopy confirmed cast iron as the base material. An upgrade to structural steel is proposed, offering the potential for improved strength-to-weight performance. Although reverse engineering and topology optimization are well-established, previous studies have largely focused on idealized models and unconstrained domains. ANSYS Workbench 2022 R1 (ANSYS Inc., Canonsburg, PA, USA) topology optimization is constrained to preserve functional interfaces and manufacturability. Motivated by the demand for lightweight automotive solutions in the Middle East, this workflow achieves 2.63% mass reduction and an estimated 6.6% cost savings based on prior benchmarks. Incorporating the Octet lattice structure (nTopology, 2022 (nTopology Inc., New York, NY, USA)) further improves performance, yielding a 6.4% mass reduction and a 16% cost reduction. The optimized design is considered a promising candidate for future additive manufacturing and Industry 4.0 implementation. This preliminary procedure provides a transferable template for redesign, static evaluation, and experimental validation of legacy components, bridging the gap between academic research and industrial practice.