Lightweight Design of a Seat Module Assembly for a Robotic Arm Amusement Ride System Using Topology Optimization

Key findings from this study

This research indicates that:

• Integrating topology optimization at the design outset enables the outer shell to function as a primary load path rather than a non-structural cover.
• Composite material selection with topology-optimized geometry reduces mass per seat by 49% relative to traditional welded metal designs.
• Bottom-up design incorporating the exterior shell geometry first, followed by internal structure integration, minimizes stress concentrations while increasing structural stiffness.

Overview

This paper presents a design methodology for lightweight seat module assemblies in robotic arm amusement rides. Traditional designs employ welded metal frames with non-structural exterior shells, creating stress concentrations and excess weight. The proposed approach applies topology optimization early in the design process, enabling the outer shell to serve as a primary load path. Fiber-reinforced polymers replace conventional metals to leverage superior stiffness-to-weight ratios.

Methods and approach

The methodology employs a bottom-up design process integrating topology optimization at the outset. After determining optimal outer shell geometry, the approach identifies ideal configurations for internal secondary framing while incorporating manufacturing constraints. Multiple manufacturing interpretations were evaluated, including extrusion and tubing-based approaches. Finite element analysis validated the final design under high-intensity load cases, verifying stress and displacement constraints.

Results

The optimized design achieved 36% reduction in overall assembly mass while increasing passenger capacity from four to five seats. This corresponds to 49% reduction in mass per seat compared to the metallic baseline. The novel curved shell geometry minimizes stress concentrations while contributing to overall structural stiffness. Finite element analysis confirmed that both stress and displacement constraints were satisfied under the specified high-intensity loading conditions.

Implications

This methodology establishes a composite-first, load-path-driven design paradigm applicable to the themed entertainment industry. Integrating topology optimization early in the design process and prioritizing the structural function of the exterior shell enables simultaneous improvements in weight efficiency and occupant capacity. The approach demonstrates feasibility across multiple manufacturing technologies, suggesting adaptability for various production environments and operational requirements.

Scope and limitations

This summary is based on the study abstract and available metadata. It does not include a full analysis of the complete paper, supplementary materials, or underlying datasets unless explicitly stated. Findings should be interpreted in the context of the original publication.