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Coursework

Linkage Arm Design Optimisation

Mass-optimised a linkage arm through hundreds of FEA iterations — ended up lightest in the third year cohort.

FEAOptimisationAbaqusFusion 360
For a third year group project I designed a linkage arm and mass-optimised it for a given load case. Hundreds of iterations of FEA across Fusion 360 and Abaqus.
Linkage Arm

Key Details

  • Shape optimisation, generative design and truss optimisation were all tried — but manual iteration proved most effective.
  • Workflow: change geometry in Fusion 360 → run 4 FEA load cases → export to Abaqus → run 4 more with a one-click Python script → iterate.
  • Final design was waterjet cut and tested. Failed almost exactly as predicted by FEA.
  • Lightest design in the third year cohort.
  • Main uncertainty: stiffness of the pinned boundary condition for out-of-plane buckling.