RBF Morph is pleased to congratulate Gabriele Bortolotto on earning his Engineering degree from the University of Rome Tor Vergata following the successful defense of his thesis, “Finite Element-Based Thermo-Structural Optimization of an Internal Combustion Engine Intake Manifold.”

Conducted under the supervision of Prof. Marco Evangelos Biancolini, with co-supervisors Ing. Riccardo Serenella and Prof. Lorenzo Bartolucci, the research demonstrates the growing role of advanced simulation technologies in accelerating engineering innovation and supporting data-driven product development.

The thesis focused on the design and optimization of a high-performance intake manifold for the Toyota G16E-GTS engine, integrating reverse engineering, CAD modeling, CFD validation, and thermo-structural finite element analysis into a comprehensive engineering workflow. Particular attention was given to the challenge of reducing component weight while maintaining strict requirements for structural integrity, durability, and manufacturability.

A central element of the study was the adoption of RBF Morph integrated within ANSYS Mechanical to perform parametric design optimization through mesh morphing. By leveraging Radial Basis Function technology, geometry modifications were applied directly to the finite element model without the need for repeated geometry reconstruction and remeshing. This approach enabled rapid evaluation of multiple design alternatives, significantly improving the efficiency of the optimization process.

The results demonstrated that advanced mesh morphing techniques can successfully support lightweight design strategies, achieving a substantial reduction in component mass while preserving compliance with pressure resistance, buckling stability, and operational safety requirements. The research highlights how simulation-driven methodologies can shorten development cycles, reduce engineering costs, and enable more informed decision-making throughout the product lifecycle.

For RBF Morph, this thesis represents another example of the successful transfer of advanced engineering technologies from research to practical industrial applications. It also reflects the importance of collaboration between academia and industry in preparing the next generation of engineers to address increasingly complex design challenges.

You can read the full thesis and the presentation.