  Although various structural optimization techniques have a sound mathematical
basis, the practical constructability of optimal designs poses a great
challenge in the manufacturing stage. Currently, there is only a limited number
of unified frameworks which output ready-to-manufacture parametric
Computer-Aided Designs (CAD) of the optimal designs. From a generative design
perspective, it is essential to have a single platform that outputs a
structurally optimized CAD model because CAD models are an integral part of
most industrial product development and manufacturing stages. This study
focuses on developing a novel unified workflow handling topology, layout and
size optimization in a single parametric platform, which subsequently outputs a
ready-to-manufacture CAD model. All such outputs are checked and validated for
structural requirements; strength, stiffness and stability in accordance with
standard codes of practice. In the proposed method, first, topology-optimal
model is generated and converted to a one-pixel-wide chain model using
skeletonization. Secondly, a spatial frame is extracted from the skeleton for
its member size and layout optimization. Finally, the CAD model is generated
using constructive solid geometry trees and the structural integrity of each
member is assessed to ensure structural robustness prior to manufacturing.
Various examples presented in the paper showcase the validity of the proposed
method across various engineering disciplines.
