The design of sandwich structures is challenging due to the large number of constituents and materials used. Existing design approaches do not include the consideration of the occurring initial damage as well as application-oriented boundary conditions in testing and optimization. Therefore, a general approach to the design optimization is presented consisting of the four parts problem definition, physical test, virtual test and design optimization, as well as an initialization phase and subsequent iterations. An exemplary application is performed for the novel design concept of optimizing the geometry of the core filling. From the initial results, the potential of the new design approach becomes clear, which can be used as a basis for the design optimization of any sandwich structures.

Aircraft cabin monuments must be optimized in terms of lightweight design, cost structure and variance. Model-based approaches support the aircraft data and help to modify them consistently during further development. In this paper, a holistic methodological approach for product families of aircraft cabin development is shown, which integrates lightweight and cost-efficient aspects, in addition to the variance focus. For this purpose, the development of cost-efficient and ligthweight optimized cabin modules is supported in a model-based way.

In this publication, the potentials of additive manufacturing in the field of sustainability and individualization for aviation and medical technology are presented. Design approaches for each application field as well as examples in the fields are shown. In the field of aviation, structures can be manufactured so that they are load path optimized. This has a great lightweight potential and results in a low resource consumption. The examples contain the design of an aircraft cabin partition using the Direct Energy Deposition process and the optimization of load introduction points directly integrated into the sandwich core. Furthermore, in medical technology, additive manufacturing can be used to produce patient-specific models based on original medical imaging data, which can be used for training of medical treatments, quality assurance or for the validation of new developed medical devices. As examples a stroke simulation model containing a modular aortic model as well as functional stenose models are shown. Furthermore, the use of AM molds to generate a deformable bladder shell and a prostate phantom are described.

No abstract

No abstract