Topology Optimization and FEA Analysis of a Brake Pedal for Additive Manufacturing

Topology optimization (TO) is a design method that aims to reduce the weight of the component and material costs while providing the required safety during operation by optimizing the shape of the part for the assumed load. This article presents a case study on mass optimization of the part from the automotive industry. The part was optimized for additive manufacturing (AM) by the Laser Powder Bed Fusion (LPBF) method. The main objective of the work carried out was to select a part with an optimization potential and reduce the weight of the part. Morphological analysis was used to select the part. The criteria of maximum overall dimensions of the part, data availability, boundary, complexity of part geometry, and material costs were taken into account. After analyzing the results of the study, a brake pedal was selected as the part for topological optimization. The brake pedal was reverse engineering from the manufacturer’s technical drawings. It was determined that the sections of the selected part are oversized. The presented case study proves that it is possible to save material/mass if AM technologies and TO methods are used for the design and manufacture of automotive parts.