Coupled Evolutionary Shape Optimization and Reverse Engineering in Product Design and Virtual Prototyping

Igor Pehnec, Damir Vučina, Željan Lozina (University of Split)

CHALLENGE - Developing products from existing designs and optimizing them for better performance and cost reduction could shorten time to market while enhancing quality standards. Redesign means facing shape optimization problems, where parameters define the geometry and the objectives.  Changes in geometry and even topology often cause problems in aligning FEM and CAD models.

​​SOLUTION - Researchers developed a systematic procedure starting from a 3D scan of an existing design to define the shape parameters for the part of the object that shall be redesigned, and develop an evolutionary shape optimization model. They created a numerical workflow in which the evolutionary optimizer chages the values of input variables to improve product performance. 

 2 x 2 chained Bezier patches representing the   wind-turbine blade








BENEFITS - modeFRONTIER saved time and resources by automatically updating optimized results through the workflow. Additionally, the procedure is very useful early on in the design stage where there is still a lot of freedom.