Utilising the new FREE topology optimisation ACT-extension, one can explore new innovative ways to reduce mass that were not available before. The DoE (Design of Experiments) approach may not be feasible if the design’s shape is not yet defined, while creating CAD models to capture all the potential design possibilities may be impossible. Now imagine starting with an arbitrary volume and having each element within either turned on or off to create the most optimum shape, taking into consideration the applied loads, boundary conditions, and design constraints (such as, a maximum displacement/stress limit required for the design) to achieve an overall weight reduction. In Shape Optimisation, we have constraints and objectives. Constraints define the optimisation’s bounds, while objectives are essentially the goal of the optimisation problem. In the following example, the imposed loadings on the Bell Crank must…