Abstract
Topology Optimization (TO) is a technique using the finite element method (FEM) that allows for increasingly efficient design of parts by optimizing material layout within a set of boundaries in order to maximize the performance of the system. The geometrical complexity of optimized configurations can be easily controlled by appropriately setting specific parameters such as preserved regions, loads, mass or displacement constraints. Using this method to design injection molds can increase the cooling speed, reduce the weight of the molds by requiring less material, and eliminate uneven shrinkage of parts. In the long run, these improvements provide a great return on investment. This thesis presents the method of designing an injection mold cavity of an arbitrary part using a Solidworks Topology study and compares the new proposed design with the traditional method by using Solidworks Flow Simulation. The TO method proves to be the better alternative offering better cooling performance, reaching the ejection temperature 4 seconds faster than traditional tooling. Time savings of approximately 67 minutes can be seen when producing 1000-qty of the parts using molds designed with the TO method. These findings highlight the importance of establishing structural topology and shape optimization in the early phases of the design/development process.