Design and Optimization of Thin-Walled Main Support Structure for Space Camera Based on Additive Manufacturing

Abstract

In order to solve the design requirements of high stiffness and lightweight for the primary support structure of a wide-field auroral imager, we propose a solution for designing and optimizing a large-scale complex thin-walled structure using additive manufacturing. Firstly, we devise an integrated thin-walled structure and test material for the main support. Secondly, shape optimization is achieved via the optimization of the lateral slope angle of the primary support based on Timoshenko cantilever beam theory. Additionally, an active fitting optimization algorithm is proposed for the purpose of refining the wall thickness of the thin-walled structure. Then, we determine the structural design of the main support. This primary support is manufactured via selective laser melting (SLM). Following processing, the structure size is 538 mm × 400 mm × 384 mm, and the mass is 7.78 kg. Finally, frequency scanning experiments indicate that, in the horizontal direction, there is a natural frequency of 105.97 Hz with an error rate of approximately 3% compared to finite element analysis results. This research confirms that our large-scale complex, thin-walled main support structure design meets all design requirements.

Editorial for the Special Issue on Laser Additive Manufacturing: Design, Materials, Processes, and Applications, 2nd Edition

“…The design of laser additive manufacturing covered in this Special Issue includes the material design (e.g., the high reflectivity and thermal conductivity multi-material 3D printing [ 22 ] and the microalloying for LPBF [ 20 ]) and the structural design (e.g., the triply periodic minimal-surface (TPMS) structure [ 18 ], the thin-walled main support structure [ 23 ]).…”

“…This Special Issue covers a wide range of forming materials, including zirconium alloys [ 24 ], titanium alloys [ 20 , 23 ], steel [ 21 , 25 , 26 ], composites (e.g., electroless copper and carbon fiber [ 27 ]), and in particular, metallic multi-materials (e.g., copper/silver [ 22 ]), 4D printing materials (e.g., NiTi, smart materials for soft interactive hydrogel [ 19 ]).…”

“…The findings of this Special Issue are expected to provide guidance and reference for scientists and engineers in the fields of aerospace (e.g., space camera and aircraft landing gear [ 23 ]), energy (e.g., fuel envelope positioning lattices of pressurized water reactors, component boxes, and heat exchangers [ 24 ]), and micromachines (e.g., four-dimensional microrobots/nanorobots [ 19 ]).…”

“…Peng et al [ 23 ] reported the design and optimization of a thin-walled main support structure for a space camera based on additive manufacturing. They proposed a solution for designing and optimizing a large-scale complex thin-walled structure using additive manufacturing.…”