The 7 Habits of Highly Effective Generative Design
A whitepaper from MSC Software / Hexagon Manufacturing Intelligence defining Generative Design as a disruptive technology that automatically creates multiple manufacturing-viable design alternatives using topology optimisation, AI and advanced simulation. It articulates seven habits — Exploration, Usability, Productivity, Costing, Sustainability, Manufacturability and First-Time-Right — and demonstrates a ~50% weight saving on a Formula Student wheel carrier at Paderborn University.
Headlines at a glance
The headline numbers and findings as they appear in the report — designed for fast scanning by leadership teams.
Average weight saving on Formula Student wheel carrier
Using MSC Apex Generative Design with Adams multi-body simulation as load input, design variants with an average weight saving of almost 50% were generated for the Formula Student wheel carrier — successfully printed and raced.
Generative Design enables replacement of multi-part fabricated assemblies with a single organic part, reducing weight, component count, assembly complexity, handling, warehousing and tolerance stack-up.
If the goal is to minimise 3D printing cost, the tool automatically checks each candidate for material required, support structure volume, machining cost for surface roughness and parts-per-build-plate maximisation.
Deppe, Reiher, Dua, Hanna, Mensing — MSC Software / Hexagon MI · 2021
What the report actually says
~50% weight saving on wheel carrier
Using MSC Apex Generative Design with Adams multi-body simulation as load input, design variants with an average weight saving of almost 50% were generated for the Formula Student wheel carrier — successfully printed and raced.
Part consolidation as weight and cost driver
Generative Design enables replacement of multi-part fabricated assemblies with a single organic part, reducing weight, component count, assembly complexity, handling, warehousing and tolerance stack-up.
Cost automation in the design loop
If the goal is to minimise 3D printing cost, the tool automatically checks each candidate for material required, support structure volume, machining cost for surface roughness and parts-per-build-plate maximisation.
First-Time-Right extends to production
The algorithm produces smooth transitions and self-supporting structures that reduce hot spots, warpage and coating-device errors — enabling first-time-right outcomes in both simulation and physical AM production.
Executive Summary
Generative Design significantly alters the conventional design cycle by leveraging topology optimisation, AI and advanced simulation to automatically create multiple viable design alternatives from simple design criteria — freeing engineers from routine geometry work.
The seven habits provide a practical framework covering Exploration (automated topology optimisation with part consolidation), Costing (automatic checks for material, support structures, surface machining and build-plate efficiency), Sustainability (weight reduction = less lifecycle energy) and First-Time-Right (self-correcting algorithm producing printable results in a single fluent process).
- A Formula Student wheel-carrier case study at Paderborn University delivered an average weight saving of nearly 50% versus the original cast-aluminium design, while Simufact Additive verification ensured all candidates were manufacturing-ready before any physical print.
Topics & sections covered
Sections drawn directly from the report's table of contents and section headings.
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Section preview
A glance at the sections inside this 12-page whitepaper.
Introduction to Generative Design
Bridging the chasm between CAE design and manufacturing
Design for Exploration
Design for Usability, Productivity, Costing, Sustainability, Manufacturability and First-Time-Right
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