AI: Generative design for structural elements

The idea to use AI to shape a structural element with given space and loads sounds simple but this task requires a different set of skills from an engineer and deeper understanding of how structure works (yes, even deeper than now).

I was using generative design to support internal parts of the device I was developing. The idea was to pack everything as neat as possible and all the parts (but casing) were supposed to be 3D printed.

Here is the model with red "no-go" zones (mostly aesthetically chosen), green "fixing points" zones and blue arrows "forces" to shape the body. You need a lot of forces in different directions, as the material is subtracted by the program to withstand only the load you added. You need to try it to understand. Starting yellow body is not shown, all-around red “no-go” zone is not shown. Second load combination "down" is not shown. 

Iteration 20

Iteration 30

Iteration 40

Iteration 50

Iteration 60

Iteration of choice 46 (aesthetics reason)

When the initial boundary conditions and forces are not set well you could get something ugly as this one (but numerically legit):

Combined renders

Steel print is too expensive so I ordered black Nylon PA12, hoping to paint it later. Paid $135 per two units, look at that beauty!

Then I tried to paint it with orange fluorescent paint but failed to get as smooth nice surface as in the render. Also fluorescent wasn't too strong even after countless layers.

The finished project

The structure feels stiff and visually interesting.