Topology Optimization for Sustainable Speaker Design

Sammanfattning

IKEA of Sweden aims to use only renewable materials by 2030. As part of this goal, this report focuses on reducing the use of ABS (Acrylonitrile Butadiene Styrene) in the speaker model VAPPEBY 20. The objective was to reduce the enclosure material by 5% using topology optimization. A literature review indicated that the most effective method would be to base the optimization on modal analysis, aiming to minimize mass while maximizing the first mode eigenfrequency. First the nominal design was analyzed using modal and structural analyses in ANSYS, and simplified component models were found to be the most efficient. Reference physical tests were also conducted in an anechoic chamber. The first eigenfrequency of the nominal design was 188 Hz, with a mass of 472 g. Subsequently, topology optimizations were carried out. The optimized results were translated into new CAD models using SolidWorks, guided by the shape of the topology results, and evaluated via modal analysis. A response surface optimization was then applied to fine-tune bracket dimensions. The optimized design achieved a first mode eigenfrequency of 190 Hz and a mass of 449.45 g, translating to potential savings of 900 kg of ABS and 2,706 $ annually. The project concludes that while topology optimization is not ideal for initial design generation of speaker enclosures, it is effective for material reduction when a reference design is available. Combined with RSO, it can provide valuable insights for future, more sustainable speaker designs.