Torx is a pretty optimized drive [1]. Otherwise, yeah, it would likely be possible. Many vendors have been proposing semi-automatic structural optimization via

Torx is a pretty optimized drive [1]. Otherwise, yeah, it would likely be possible. Many vendors have been proposing semi-automatic structural optimization via finite element methods for a while now (for example, [2]). I'd assume it'd be pretty long running though, as its a non-linear contact problem likely needing pretty tight tolerances/meshing. In the real world though, you're much more likely to want something standard. [1] http://en.wikipedia.org/wiki/Torx http://en.wikipedia.org/wiki/Torx [2] http://www.altairhyperworks.com/HWTemp3Product.aspx?product_id=19&item_name=Benefits http://www.altairhyperworks.com/HWTemp3Product.aspx?product_...