GD Bumper

Project context

For the Dutch police, I developed a lightweight yet impact-absorbing bumper for a remote-controlled vehicle. The main challenge was to create a design that could absorb collisions effectively without compromising the vehicle’s performance.

Approach

Using the IPO design process combined with generative design and topology optimization, I engineered a structure that provided maximum strength at minimal weight. The design included a controlled deformation area to absorb shocks in a predictable way.
Due to confidentiality agreements, specific technical details and performance data cannot be shared.

Tools & Techniques

• IPO design process

• Generative design & topology optimization

• CAD modeling

• Additive manufacturing

• Structural design & failure zone engineering

Outcome

Reflection

The result was a high-quality TPU bumper, 3D printed with a laser printer. The product combined lightweight design with optimized impact resistance, offering a durable and practical solution tailored to the police’s operational requirements.

This project deepened my expertise in simulation-driven design and additive manufacturing. It taught me how to combine topology optimization with real-world material behavior to create products that are not only innovative, but also highly functional.