Shape Optimization & Generative Design

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.