Influence of Manufacturing Constraints on Generative Design Outcomes: A Lightweight Automotive Brake Pedal Case Study
DOI:
https://doi.org/10.24237/djes.2025.18413Keywords:
Generative Design, Design for Manufacturability, Topology Optimization, Additive Manufacturing, Automotive Brake PedalAbstract
Generative design is a technique that effectively produces lightweight yet structurally robust components. However, the final result is highly dependent upon manufacturing constraints during the design phase. This work investigates how machining, 3D printing, and die casting constraints shape a reengineered car brake pedal. Each option was constructed within Autodesk Fusion 360 using identical loads and fixations and material characteristics. Variations in performance were evaluated by FEA with respect to weight, stress pattern, stiffness, movement under load, and safety margin. In contrast, the greatest mass reduction was attained by the AM-based design; the mass dropped from 1.36 kg to 0.58 kg, a 41.3% drop, while still meeting the minimum required safety margin of at least 2.0. Meanwhile, the average mass for the die-cast design reached 0.70 kg, based on proper taper and thickness rules of the part while maintaining strength. On the contrary, the machined-limited part had the heaviest mass value of 2.77 kg. Nevertheless, it portrayed the highest stiffness; besides that, it attained the highest safety value, FoS = 5.84, highlighting how subtractive manufacturing methods sacrifice mass for durability. Manufacturing limits impact geometric design results by limiting feasible forms while varying mechanical component functionalities. Accordingly, this paper presents an investigation into different manufacturing techniques and their impacts on design solutions, using examples of different techniques to highlight efficiency. Ways of proposing lighter brake pedal designs that are easier to produce involve adjusting material usage while easing assembly steps to enhance feasibility without compromising performance.
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Copyright (c) 2025 Mohd Nizam Sudin, Mohd Asri Yusuff, Faiz Redza Ramli, Abd Rafeq Saleman, Arzul Arifin
This work is licensed under a Creative Commons Attribution 4.0 International License.
