Design-informed generative modelling of skeletal structures using structural optimization

Although various structural optimization techniques have a sound mathematical basis, the structural robustness and practical constructability of optimal designs pose a great challenge in the manufacturing stage. This paper presents an automated novel approach stemming from structural optimization and engineering principles, where discrete members of the structurally optimized designs are driven towards optimal utilization. The developed workflow unifies topology, layout and size optimization in a single parametric platform, which subsequently outputs a ready-to-manufacture CAD skeletal model which can be manufactured either additively or by assembly. All such outputs are checked and validated for structural requirements; strength, stiffness and stability in accordance with standard codes of practice. In the implementations, first, a topology-optimal model is generated and converted to a one-pixel-wide chain model using skeletonization. Herein, this paper uses a novel efficient method to extract the skeleton by using pixel-padding near the domain borders. Secondly, a spatial frame is extracted from the skeleton for its member size and layout optimization. Finally, the CAD model is generated using constructive solid geometry trees and the structural integrity of each member is assessed to ensure structural robustness prior to manufacturing. Various examples presented in the paper showcase the validity of the presented workflow across various structural engineering applications.