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The development of the additive manufacturing technology has enabled the design of components with complex structures that were previously unfeasible with conventional techniques. Among them, the Triply Periodic Minimal Surface (TPMS) structures are gaining scientific interest in several applications. Thanks to their high surface-to-volume ratio, lightweight construction, and exceptional mechanical properties, TPMS structures are being investigated for the production of high-performance heat exchangers to be adopted in different industrial fields, such as automotive and aerospace. Another significant advantage of the TPMS structures is their high degree of design flexibility. Each structure is created by replicating a characteristic unit cell in the three spatial dimensions. The three key parameters, namely cell type, cell dimension and wall thickness can be adjusted to provide considerable versatility in the design process.

The new corner-based architecture of electrified road vehicles requires a redesign of vehicle suspension components. The design protocol must satisfy the target parameters derived from dynamics requirements. The roll stiffness of the anti-roll bar is a crucial parameter for the handling performance of a vehicle. During the development of a new suspension, the design of the anti-roll bar needs to be modified. To this aim, two-dimensional beam theory models can quickly provide a preliminary design of this component. However, the simplified models might be inaccurate due to the three-dimensional and complex shapes of the bars. The present study aims to overcome this limitation. An analytical beam model based on the spline description of the bar has been developed, which is accurate even for complex geometries of the bars. Assuming a hollow and closed circular cross-section, the model returns the average diameter and the radial thickness needed to achieve the stiffness performance.

Modern high performance engines are usually characterized by high power densities, which lead to high mechanical and thermal loadings acting on engine components. In this scenario, aluminum may not represent the best choice for piston manufacturing and steel may be considered as a valid alternative. In this article, a methodology involving optimization techniques is presented for the design of an internal combustion engine piston. In particular, a design strategy is preliminary investigated aiming at replacing the standard aluminum piston, usually manufactured by forging or casting, with an alternative one made of steel and manufactured via an Additive Manufacturing process. Three different loading conditions are employed for the topology optimizations setup. Optimization results are then interpreted and the various structural features of the steel piston are designed starting from the density distribution contour plots.