Generative Lightweighting of Actuator-Integrated Robotic Structures Under Decentralized Additive Manufacturing Constraints

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Volume: 12 | Issue: 1 | Year 2026 | Subscription
International Journal of Mechanics and Design
Received Date: 02/26/2026
Acceptance Date: 02/27/2026
Published On: 2026-03-15
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By: Pedro Portugal.

School of Engineering and Sciences, Tecnológico de Monterrey

Abstract

This study presents the implementation and structural validation of a constraint-driven generative design methodology for the development of lightweight actuator-integrated robotic components fabricated using decentralized additive manufacturing. Building upon a previously formalized constraint-driven framework, the method was applied to the synthesis of a modular robotic link representative of actuator-integrated structural elements commonly used in legged robotic systems. The baseline component was defined to preserve critical functional interfaces, including actuator mounting geometry, modular mechanical connections, and fabrication feasibility within consumer-grade fused deposition modeling environments. Generative refinement was performed within a bounded design space under representative quasi-static loading conditions derived from worst-case operational scenarios. The resulting geometries demonstrated clear structural redistribution along primary load paths, producing mechanically interpretable and fabrication-ready designs without compromising functional interface integrity.

Comparative structural evaluation using finite element analysis indicated improved stress distribution and a mass reduction of up to 64.9% relative to the baseline design, while maintaining acceptable structural safety margins. The optimized component was successfully fabricated using consumer-grade additive manufacturing without requiring post-generation geometric correction, support-driven redesign, or dimensional compensation. Dimensional inspection and analytical dynamic validation confirmed structural plausibility under representative operational loading conditions. These results demonstrate that constraint-driven generative design enables the reliable synthesis of actuator-integrated robotic components that are lightweight, mechanically credible, and directly manufacturable using decentralized additive manufacturing. The methodology provides a practical pathway for improving structural efficiency and manufacturability in modular robotic systems developed outside centralized industrial production environments.

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How to cite this article: Pedro Portugal Generative Lightweighting of Actuator-Integrated Robotic Structures Under Decentralized Additive Manufacturing Constraints. International Journal of Mechanics and Design. 2026; 12(1): -p.

How to cite this URL: Pedro Portugal, Generative Lightweighting of Actuator-Integrated Robotic Structures Under Decentralized Additive Manufacturing Constraints. International Journal of Mechanics and Design. 2026; 12(1): -p. Available from:https://journalspub.com/publication/ijmd/article=26019

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