14 Int. J. Product Development, Vol. 14, Nos. 1–4, 2011 Copyright © 2011 Inderscience Enterprises Ltd. Integration of topology optimisation tools and knowledge management into the virtual Product Development Process of automotive components Maurizio Muzzupappa*, Loris Barbieri and Fabio Bruno Dipartimento di Meccanica, Università della Calabria, Rende (CS), Italy Fax: (+39) 0984 494673 E-mail: muzzupappa@unical.it E-mail: loris.barbieri@unical.it E-mail: f.bruno@unical.it *Corresponding author Abstract: This paper presents a methodology in which CAD, a multi-body simulator and a Topological Optimisation (TO) tool are synergically employed to support the design of a suspension component. In particular, the methodology defines some guidelines and introduces two knowledge-based interfaces able to facilitate the integration of TO of the component within a standard design process. To illustrate this capability, the process is applied to the conceptual design of the Upright for a Formula SAE prototype. The results show that the integrated design approach can efficiently support the selection of the optimum conceptual design of a mechanical component with complex dynamic behaviour, in particular when very little previous experience on the system is available. Keywords: knowledge-based engineering; integrated approach; multi-body; TO; topological optimisation; virtual product development. Reference to this paper should be made as follows: Muzzupappa, M., Barbieri, L. and Bruno, F. (2011) ‘Integration of topology optimisation tools and knowledge management into the virtual Product Development Process of automotive components’, Int. J. Product Development, Vol. 14, Nos. 1–4, pp.14–33. Biographical notes: Maurizio Muzzupappa is an Associate Professor of Computer-Aided Design at the Department of Mechanical Engineering, Università della Calabria. He earned his PhD in Mechanics of the Materials from the Università di Pisa in 1992. His current research activities include applications of Virtual and Augmented Reality (VR&AR) to the design process of the industrial products, concurrent engineering, interface design and usability, CAD automation and reverse engineering. Loris Barbieri is a PhD student in Mechanical Engineering at Università della Calabria. He received a Masters Degree in Mechanical Engineering from Università della Calabria in 2006. His current research interests include computer applications in PDP, development of KBE systems and CAD automation.