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Engineering — ME 127 Algorithmic Modeling · Winter 2026

Shape Optimization & Generative Design

Sebastian Esteva  ·  Stanford University  ·  Biomechanical Engineering

The question this project kept asking: how much material can you remove before things go wrong? Starting with FEA on an existing machining gripper, I used shape optimization to find where the stress actually lives, then ran generative design across three materials (Aluminum 6061, Stainless Steel 304, ABS) and three manufacturing methods (unrestricted, additive, 2-axis). ABS additive won — it hit the safety factor and could actually be printed in the lab.

Key topics: FEA · shape optimization · generative design · Fusion 360 · additive manufacturing · materials comparison

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