Figure 4
Three design stages show force constraints, generative optimisation iteration, and final optimised gear structure.The three engineering illustrations show the generative design optimisation process for a gear component. Model A presents force and constraint conditions applied to a gear model, including arrows indicating fully constrained regions and applied force directions, with a horizontal scale from 0 to 80 millimetres. Model B displays the best optimisation iteration featuring an internal lattice-like structural pattern within the gear body, alongside x, y, and z coordinate axes. Model C shows the final optimised gear assembly with separate upper and lower sections and integrated internal support structures.

Generative gear model, applied loading conditions and final optimized design used for fabrication and validation

Source: Authors’ own work

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