Exploring the cost and lifetime benefits of a topology optimized aerospace part applying additive manufacturing

The aerospace sector is characterized by long product life cycles and a need for lightweight design. Additive manufacturing is a technology that produces parts layer by layer and thus enables the manufacturing of any complex parts at nearly no extra costs. A topology optimization enhances the part’s performance for their special purpose. The results are often complex bionic structures that cannot be produced with conventional manufacturing technologies. The paper analyzes how the high potential of this technology can be applied to aerospace parts. A topology optimization will be conducted for an aircraft part explaining the crucial points and a life cycle analysis examines the achieved sustainable improvements for the aircraft’s life cycle.