Topology optimization and additive manufacturing for aerospace components

One of the main challenges for the aerospace industry nowadays lies in weight reduction of aircraft components without compromising their structural functionalities. With that goal, structural and topology optimization show up as a combination of design and modelling techniques. Based on the finite element method (FEM), component optimization consists of removing material which is dispensable, keeping proper functioning of the modelled part. The result is an optimized geometry, usually with a complex shape, which is possible to manufacture thanks to additive manufacturing (AM) technologies. In this paper, the topological optimization methodology has been used to redesign the following components: (1) a connector support of the VEGA space launcher, (2) a typical lever component from civil aircrafts and (3) housing part from fan cowl structures. In all of the cases, a significant weight reduction has been reached without major impact on their mechanical behaviour. Finally, components (1) and (2) were manufactured by laser beam melting (LBM) technology to demonstrate the possibility of the couple, optimization and AM concepts, as a way to improve the future aerospace structures.