Topology optimization of cable car

At SimulaX Engineering, we recently supported one of our clients with a topology optimization study aimed at reducing the weight of a structural component while maintaining strength and manufacturability.

The component was supported from the top by a cylindrical constraint, while four holes at the bottom were subjected to 1 kN bearing loads each, applied vertically downward. The goal was to minimize the overall mass of the structure while keeping stresses below the allowable limits, maintaining a minimum safety factor of 3.

The material used in the simulation was structural steel, and the optimization was performed using our finite element–based topology optimization workflow. In this process, the solver iteratively redistributes material within a given design space, removing regions with low load contribution while retaining material in areas critical for load transfer.

Within a single day, the optimization revealed a design concept that achieved a 49% reduction in weight, without any significant stress increase in the remaining structure.

However, our work didn’t stop there . We also ensured the optimized design could be manufactured efficiently. The topology result was refined and translated into a production-ready geometry, preserving the optimized load paths while introducing manufacturable features such as proper fillets, uniform wall thickness, and machining-friendly surfaces.

This project clearly demonstrates how simulation-driven design can drastically reduce development time and material usage, while guiding engineers toward smarter, lighter, and more robust designs.