Article: Lightweight design of automotive parts based on the FPTO method Journal: International Journal of Vehicle Systems Modelling and Testing (IJVSMT) 2026 Vol.20 No.2 pp.159 - 179 Abstract: Topology optimisation is a method to maximise or minimise an objective function by optimising material distribution under design constraints. In the theoretical research of topology optimisation, most algorithms are developed on regular geometric models in software such as MATLAB. However, applying these findings directly to complex structures with irregular geometries in engineering is challenging. Optimisation of such structures relies on commercial software using density-based methods, hindering open algorithm research. The floating projection topology optimisation (FPTO) is a stable, efficient method producing good results. This study introduces the FPTO principles and investigates its integration on the MATLAB-ABAQUS platform, including conducting analysis in ABAQUS, performing optimisation solution and result visualisation in MATLAB, and facilitating data exchange. The boundaries of the topology structure are smoothed to better meet actual engineering requirements. This research explores the application of FPTO to automotive components, achieving lightweight designs for wheel hubs and control arms, offering an effective engineering solution. Inderscience Publishers - linking academia, business and industry through research

Title: Lightweight design of automotive parts based on the FPTO method

Authors: Dengfeng Huang; Xuwei Hu; Xiaolei Yan

Addresses: Fujian Key Laboratory of Automotive Electronics and Electric Drive, Fujian University of Technology, Fuzhou, 350118, China ' Fujian Key Laboratory of Automotive Electronics and Electric Drive, Fujian University of Technology, Fuzhou, 350118, China ' Fujian Key Laboratory of Automotive Electronics and Electric Drive, Fujian University of Technology, Fuzhou, 350118, China

Abstract: Topology optimisation is a method to maximise or minimise an objective function by optimising material distribution under design constraints. In the theoretical research of topology optimisation, most algorithms are developed on regular geometric models in software such as MATLAB. However, applying these findings directly to complex structures with irregular geometries in engineering is challenging. Optimisation of such structures relies on commercial software using density-based methods, hindering open algorithm research. The floating projection topology optimisation (FPTO) is a stable, efficient method producing good results. This study introduces the FPTO principles and investigates its integration on the MATLAB-ABAQUS platform, including conducting analysis in ABAQUS, performing optimisation solution and result visualisation in MATLAB, and facilitating data exchange. The boundaries of the topology structure are smoothed to better meet actual engineering requirements. This research explores the application of FPTO to automotive components, achieving lightweight designs for wheel hubs and control arms, offering an effective engineering solution.

Keywords: topology optimisation; floating projection; MATLAB-ABAQUS platform; complex structures.

DOI: 10.1504/IJVSMT.2026.153190

International Journal of Vehicle Systems Modelling and Testing, 2026 Vol.20 No.2, pp.159 - 179

Received: 23 Dec 2024
Accepted: 02 Jul 2025
Published online: 29 Apr 2026 *

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Title: Lightweight design of automotive parts based on the FPTO method

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