Revolutionary Superposition Layout Method for Topology Optimization of Non-Concurrent Multi-load Models: Connecting-Rod Case Study Mohamed G. Alkalla 1,2∗ | Mahmoud Helal 2,3 | Ahmed Fouly 4,5 1 Surrey Space Centre, University of Surrey, Guildford, GU2 7XH, UK 2 Production Engineering & Mechanical Design Dept., Mansoura University, 35516, Egypt 3 Department of Mechanical Engineering, Faculty of Engineering, Taif University, Al-hawyah, P.O. Box 888, Saudi Arabia 4 Mechanical Engineering Department, College of Engineering, King Saud University, Riyadh, 11421, Saudi Arabia 5 Department of Production Engineering & Mechanical Design, Faculty of Engineering, Minia University, 61519, Egypt. Correspondence Corresponding author, Mohamed G. Alkalla, Tel: +44 (0)7927291000 Email: m.alkalla@surrey.ac.uk, m_elkalla@mans.edu.eg Funding information This article proposes a new approach called revolutionary superposition layout (RSL) for obtaining optimum designs of non-concurrent multi-loads structures in general, and for connecting rod (CR) in particular. Since the compression and tension resulted from the combustion and exhaust strokes are non-concurrent loads, the importance of this approach arises up. RSL depends on combining the optimum-design layouts obtained from different individual non-concurrent load cases into one resultant design. This final design efficiently sustains all different loads applied to it. RSL presents a simple, less computational effort in the dynamic environment, and less time-consuming method. RSL has been compared with a multi-load optimization method called bound formulation (BF) for obtaining the optimum design of some simple models before dealing with the CR model afterward. Two distinctive optimum topological designs of CR produced by RSL have proved their feasibility and achieved considerable im- provements against both the conventional CR design being used nowadays in the automotive industry and the BF method designs, as well. A comparative study between them was accomplished based on both structural and modal analyses in ANSYS. As a result, the proposed RSL design shows a significant reduction of compliance, displacement/deflection and mass moment of inertia by 57.2%, 68.7% and 5.9%, respectively, compared to conventional one. KEYWORDS Connecting Rod, Revolutionary Superposition Layout (RSL) Topology Optimization, Non-Concurrent Multi-loads Accepted Article This article is protected by copyright. All rights reserved. This article has been accepted for publication and undergone full peer review but has not been through the copyediting, typesetting, pagination and proofreading process which may lead to differences between this version and the Version of Record. Please cite this article as doi: 10.1002/nme.6582