Mass Reduction versus Structural Integrity in Topology‐Optimized Parametric Components

ABSTRACT

This research examines the application of topology optimization in achieving a lightweight design for finger splints while maintaining anatomical accuracy and ensuring user comfort requirements are met. A parametric baseline model was designed, and two optimized concepts were created utilizing topology‐based algorithms in Fusion 360. Each design underwent finite element analysis under physiologically relevant loading conditions that reflect typical tendon forces on an immobilized distal phalanx. Analyzed outputs included mass, safety factor, maximum stress, and equivalent strain. Topology optimization reduced mass by about 21.5% for concept 1 and 43.7% for concept 2, but caused safety factors to drop by roughly 70% and 95%, with stress and strain increasing by 18 times for the second concept. The conducted analysis reveals a nonlinear correlation between material removal and mechanical integrity, highlighting a critical threshold at which stiffness and safety decline significantly. These results show the importance of incorporating constraint‐aware and anatomically informed topology optimization in the design of medical devices. Future work will explore hybrid approaches combining minimum thickness enforcement, fillet optimization, internal ribbing, and lattice infill strategies to balance mass efficiency and biomechanical safety.