Design optimization and validation for additive manufacturing: a satellite bracket application

Gökdağ, İstemihan; İzgü, Orçun; Dağkolu, Akın; Tanrıkulu, Ahmet Alptuğ; Acar, Erdem

doi:10.1007/s00158-022-03345-3

Cited by 6 publications

(2 citation statements)

References 34 publications

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“…One study [163] focused on designing a lightweight satellite bracket, reducing mass while ensuring structural integrity under various loads. Employing the SIMP method through Altair OptiStruct®, the researchers achieved a 25% mass reduction in comparison to the original design to manufacture on CNC.…”

Section: Cases Of Study Regarding the Simp Methodmentioning

confidence: 99%

Iterative design of satellite structures and topology optimisation methods

Hurtado-Pérez,

Pablo-Sotelo,

Ramírez-López

et al. 2024

J. Phys.: Conf. Ser.

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Satellite launches are critical amid increasing demands for advanced services. Rising costs urge innovation in engineering. Enhancing satellite structural integrity during launches is crucial due to intense vibrations. Topology optimisation and additive manufacturing converge as promising solutions. Topology optimisation uses mathematical techniques to iteratively improve structures by reducing mass while enhancing attributes like load capacity. This field, active for about three decades, employs continuum and discrete algorithms to optimise structures. Recent trends show optimised structures through topology optimisation and additive manufacturing promise cost-effective and high-performance solutions. This study aims to extensively review topology optimisation methods, specifically focusing on satellite structures, to shape future developments within the years to come.

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Section: Cases Of Study Regarding the Simp Methodmentioning

confidence: 99%

Iterative design of satellite structures and topology optimisation methods

Hurtado-Pérez,

Pablo-Sotelo,

Ramírez-López

et al. 2024

J. Phys.: Conf. Ser.

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“…The work in [497] presents a combination of TO and AM to design, analyse, manufacture, and qualify a lightweight satellite bracket. Lightweight aerospace structures can significantly improve performance and reduce emission but their design optimisation and manufacturing is challenging.…”

Section: Solid Isotropic Materials Interpolation Methodsmentioning

confidence: 99%

On Topology Optimisation Methods and Additive Manufacture for Satellite Structures: A Review

Hurtado-Pérez,

Pablo-Sotelo,

Ramírez-López

et al. 2023

Aerospace

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Launching satellites into the Earth’s orbit is a critical area of research, and very demanding satellite services increase exponentially as modern society takes shape. At the same time, the costs of developing and launching satellite missions with shorter development times increase the requirements of novel approaches in the several engineering areas required to build, test, launch, and operate satellites in the Earth’s orbit, as well as in orbits around other celestial bodies. One area with the potential to save launching costs is that of the structural integrity of satellites, particularly in the launching phase where the largest vibrations due to the rocket motion and subsequent stresses could impact the survival ability of the satellite. To address this problem, two important areas of engineering join together to provide novel, complete, and competitive solutions: topology optimisation methods and additive manufacturing. On one side, topology optimisation methods are mathematical methods that allow iteratively optimising structures (usually by decreasing mass) while improving some structural properties depending on the application (load capacity, for instance), through the maximisation or minimisation of a uni- or multi-objective function and multiple types of algorithms. This area has been widely active in general for the last 30 years and has two main core types of algorithms: continuum methods that modify continuous parameters such as density, and discrete methods that work by adding and deleting material elements in a meshing context. On the other side, additive manufacturing techniques are more recent manufacturing processes aimed at revolutionising manufacturing and supply chains. The main exponents of additive manufacturing are Selective Laser Melting (SLM) (3D printing) as well as Electron Beam Melting (EBM). Recent trends show that topology-optimised structures built with novel materials through additive manufacturing processes may provide cheaper state-of-the-art structures that are fully optimised to better perform in the outer-space environment, particularly as part of the structure subsystem of novel satellite systems. This work aims to present an extended review of the main methods of structural topology optimisation as well as additive manufacture in the aerospace field, with a particular focus on satellite structures, which may set the arena for the development of future satellite structures in the next five to ten years.

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