Topology Optimization of an Aerospace Bracket: Numerical and Experimental Investigation

Abstract

The integration of topology optimization into additive manufacturing provides unmatched possibilities for the sustainable manufacturing of lightweight, intricate, custom parts with less material at a lower production time and cost. This study aims to apply and benchmark topology optimization methods, in conjunction with additive manufacturing, to enhance the design of functional components used in aerospace applications, while simultaneously providing an experimental verification and comparative analysis of such optimization techniques. This approach was applied to an industrial bracket used in aerospace applications, which was optimized with the aim of weight reduction without sacrificing its original mechanical stiffness. A density-based technique and a level-set method were used to perform the analysis and optimization, whereas fabrication was performed using fused deposition modeling. Finally, a compression and tensile testing machine was employed for the testing, verification, and comparison of the exhibited mechanical strength for the whole range of printed parts, under the same load conditions. The optimized designs achieved a 20% weight reduction while maintaining the compression displacement of the initial components at the given load. The achieved results demonstrate that topologically optimized components can significantly enhance the design of real-life components, such as those used in the weight-sensitive industrial applications considered in this work.

Keywords

• additive manufacturing
• topology optimization
• level-set method
• density-based method