Redesign for AM of a metal component through topology optimization: a case study

At the design stage of a component, manufacturing constraints, related to the geometry, have to be applied in order to reduce manufacturing costs and the lead-time. Consequently, the final design for manufacturability could be very different from the optimal design, in terms of technical performances. Currently, classical manufacturing constraints can be removed and complex functional parts can be built cost-effectively through the use of metal additive manufacturing (AM) processes. The design freedom offered by AM can be exploited through certain techniques, such as topology optimization (TO). Thus, the performances of end-usable components that are currently produced through traditional manufacturing processes can be improved significantly. One of the main applications is that pertaining to the lightening of components through structural optimization. This study presents an industrial case in which the advantages of free- constraint TO and AM are exploited to increase the stiffness of the component, while preserving the original weight. The presented case study pertains to a small aluminium bracket, which is used to support a flying measurement probe. Since displacement control was one of the requirements in the case study, and because of certain TO software limitations, several iterations have been necessary, in terms of design space definition. The final design provides a reduction of about 50% in the displacements. Moreover, a weight reduction of about 10% has been achieved.