• Rohit
• Ganga Singh
• Dinesh Kumar

The optimization of mechanical components through computational design methods has become increasingly critical in modern engineering applications. This comprehensive review examines the state-of-the-art approaches in topology optimization and finite element analysis for brake lever components, with emphasis on weight reduction, structural performance enhancement, and sustainability. The review synthesizes recent developments in Computer-Aided Engineering tools, specifically CATIA and ANSYS platforms, and their application in automotive component design. Advanced optimization techniques including the Solid Isotropic Material with Penalization method and shape optimization algorithms are critically evaluated. The integration of lightweight materials, particularly aluminum alloys, with optimization strategies demonstrates significant potential for achieving substantial mass reduction while maintaining structural integrity. This review identifies key research gaps and proposes future directions for the development of lightweight, high- performance brake components suitable for modern two-wheeler applications. The findings indicate that topology optimization can achieve mass reductions of 20-60% while improving stress distribution and fatigue life, making it an essential tool for sustainable automotive design.

Topology optimization, Finite element analysis, Brake lever, Lightweight design, SIMP method, ANSYS, CATIA

"Topology and Shape Optimization of Brake Lever for Two-Wheelers Featuring Comprehensive Review of CAD-FEA Integration and Manufacturing Applications", International Journal of Emerging Technologies and Innovative Research (www.jetir.org), ISSN:2349-5162, Vol.12, Issue 12, page no.a192-a210, December-2025, Available :http://www.jetir.org/papers/JETIR2512026.pdf

"Topology and Shape Optimization of Brake Lever for Two-Wheelers Featuring Comprehensive Review of CAD-FEA Integration and Manufacturing Applications", International Journal of Emerging Technologies and Innovative Research (www.jetir.org | UGC and issn Approved), ISSN:2349-5162, Vol.12, Issue 12, page no. ppa192-a210, December-2025, Available at : http://www.jetir.org/papers/JETIR2512026.pdf