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Optistruct solution sticking to design boundary

I am a university student trying to run topology optimisation for a part I'm designing.
I am having an issue where the solution that I get is sticking to the boundary of the design area but I would like it to produce a solution that isn't pushing up closely to these boundaries.
I know if I had the Draw constraint on for my optimisation I could use the Stamp option which forces the design to evolve into a 3D structure which isn't connected to the boundary. (At least that's how I understand it to work but it doesn't matter as I'm not using the Draw constraint).

Can someone advise how I can achieve this.

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HyperMesh

OptiStruct

v2024

Accepted answers

GTT Johan

Hi Tom
If the optimisation takes space close to your outer limiting faces it indicates that it is beneficial to put material there. If you are allowed to increase design space you can do that until you have captured a region that is not needed in the optimisation!
But your case is pretty standard if one have limiting package room for a design!
So nothing wrong with the set-up!

Kind regards
Johan

All comments

GTT Johan

TomSouthall

Hi Tom
If the optimisation takes space close to your outer limiting faces it indicates that it is beneficial to put material there. If you are allowed to increase design space you can do that until you have captured a region that is not needed in the optimisation!
But your case is pretty standard if one have limiting package room for a design!
So nothing wrong with the set-up!

Kind regards
Johan

Unfortunately I can't change the design space. I know that this shows that it is beneficial to have material here however when it pushes up close tho the edge of the design space like this it makes the solution unrealistic to manufacture and requires work to make a producible equivalence.
Is there a way that I can force the solution to have some separation from the boundary?

Adriano_Koga

Unfortunately I can't change the design space. I know that this shows that it is beneficial to have material here however when it pushes up close tho the edge of the design space like this it makes the solution unrealistic to manufacture and requires work to make a producible equivalence.
Is there a way that I can force the solution to have some separation from the boundary?

honestly, topology optimization won't give you a 100% manufacturable design right away.

If there's no much room for growing the design area, then you already have the solution, and this area is really necessary for the design.

In order to make it more feasible, you would need to work on the next phase, on post-processing the design solution into a CAD, i.e., and making sure these region is smoothened.

Or you could go to Inspire and generate some sort of PolyNURBS from this response.