Devolopment, Production and post-processing of a topology optimized aircraft bracket - Klippstein, Sven Helge; Duchting, Anne; Reiher, Thomas; Hengsbach, F.; Menge, Dennis; Schmid, Hans-Joachim (30th Annual International Solid Freeform Fabrication Symposium, 2019)
Structural parts for aviation have very high demands on the development and production process. Therefore, the entire process must be considered in order to produce high-quality AM metal parts. In this case study, a conventional part was selected to be optimized for AM. The process presented includes component selection, design improvement with a novel approach for topology optimization based on the AMendate algorithm as basis of MSC Apex Generative Design,component production on a SLM 250 HL and post-processing including heat treatment and surface smoothing. With the topology optimization a weight reduction of ~60 % could be realized, whereby the stress distribution is more homogeneous. Furthermore, the challenges of support optimization and post-processing have to be addressed, in order to produce competitive parts.
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Keywords: conference paper