Lightweighting using shells: An exploration of generatively designed hollow structures

Despite the lightweighting benefts that hollow structures afford, current Generative Design (GD) tools are not capable of synthesising them by default. This paper proposes an approach to generate hollow structures using an off-the-shelf GD tool and an innovative shelling method. The approach is used to create solid and hollow variants of a load bearing component. These are modelled using Finite Element Analysis (FEA) then Additively Manufactured (AM) and characterised via destructive load testing. FEA results show that the shelled structures are up to 2.5 x stiffer than their solid counterparts however destructive testing revealed small stiffness losses attributable to the AM process. Despite the physical testing results the method offers the potential to apply GD tools to industries where hollow tubes are accepted practice, enabling part consolidation capabilities to be leveraged.