Designing for Additive Manufacturing: Lightweighting Through Topology Optimization Enables Lunar Spacecraft

Orme, Melissa; Gschweitl, Michael; Ferrari, Michael; Madera, Ivan; Mouriaux, Franck

doi:10.1115/1.4037304

Cited by 75 publications

(34 citation statements)

References 8 publications

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“…Due to the general lack of understanding of AM processes and lack of standards, the approach to qualification of AM parts has so far been on a part-by-part and process basis, relying on both destructive and non-destructive testing (NDT) [21]. Examples of this approach for space applications can be found in literature, for example, References [11,12]. Hence, in order to establish a qualification approach (and AM requirements frameworks), organizations need to build AM understanding concurrently with the development of AM products, based on testing and inspection.…”

Section: Challenges With Qualification Of Additive Manufacturing Partsmentioning

confidence: 99%

“…In order to achieve such drastic cost reductions for space applications, new industrial system set-ups are needed, combined with extreme design-to-cost, efficient product development and the use of AM [8,9]. Examples of AM space components that have been used in service are brackets for satellite antennas [10], brackets for spacecraft waveguides [11] and lunar lander engine mounts [12,13]. In general, however, information about the criticality level of AM parts that have been used in service is limited [3] and well-described examples of AM used for critical parts are lacking.…”

Section: Introductionmentioning

confidence: 99%

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A Design for Qualification Framework for the Development of Additive Manufacturing Components—A Case Study from the Space Industry

Dordlofva

2020

Aerospace

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Additive Manufacturing (AM) provides several benefits for aerospace companies in terms of efficient and innovative product development. However, due to the general lack of AM process understanding, engineers face many uncertainties related to product qualification during the design of AM components. The aim of this paper is to further the understanding of how to cope with the need to develop process understanding, while at the same time designing products that can be qualified. A qualitative action research study has been performed, using the development of an AM rocket engine turbine demonstrator as a case study. The results show that the qualification approach should be developed for the specific application, dependent on the AM knowledge within the organization. AM knowledge is not only linked to the AM process but to the complete AM process chain. Therefore, it is necessary to consider the manufacturing chain during design and to develop necessary knowledge concurrently with the product in order to define suitable requirements. The paper proposes a Design for Qualification framework, supported by six design tactics. The framework encourages proactive consideration for qualification and the capabilities of the AM process chain, as well as the continuous development of AM knowledge during product development.

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Section: Challenges With Qualification Of Additive Manufacturing Partsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

A Design for Qualification Framework for the Development of Additive Manufacturing Components—A Case Study from the Space Industry

Dordlofva

2020

Aerospace

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“…However, current design for manufacturing techniques have been developed largely for conventional manufacturing processes [1]. Therefore, to take advantage of the design freedom enabled by AM processes, design for additive manufacturing (DfAM) methods need to be developed [1,2]. Representative DfAM methodologies include cellular structure design, topology optimization (TO), manufacturability analysis for AM, and other design approaches that can make use of the AM-enabled features [1].…”

Section: Introductionmentioning

confidence: 99%

Design and Optimization of Graded Cellular Structures With Triply Periodic Level Surface-Based Topological Shapes

Dai

Tang

et al. 2019

Journal of Mechanical Design

108

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Periodic cellular structures with excellent mechanical properties widely exist in nature. A generative design and optimization method for triply periodic level surface (TPLS)-based functionally graded cellular structures is developed in this work. In the proposed method, by controlling the density distribution, the designed TPLS-based cellular structures can achieve better structural or thermal performances without increasing its weight. The proposed technique can be divided into four steps. First, the modified 3D implicit functions of the triply periodic minimal surfaces are developed to design different types of cellular structures parametrically and generate spatially graded cellular structures. Second, the numerical homogenization method is employed to calculate the elastic tensor and the thermal conductivity tensor of the cellular structures with different densities. Third, the optimal relative density distribution of the object is computed by the scaling laws of the TPLS-based cellular structures added optimization algorithm. Finally, the relative density of the numerical results of structure optimization is mapped into the modified parametric 3D implicit functions, which generates an optimum lightweight cellular structure. The optimized results are validated subjected to different design specifications. The effectiveness and robustness of the obtained structures is analyzed through finite element analysis and experiments. The results show that the functional gradient cellular structure is much stiffer and has better heat conductivity than the uniform cellular structure.

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“…Accordingly, TO provides to the designer a great freedom, allowing complex structures, not immediately imaginable with traditional design methodologies [5].…”

Section: Introductionmentioning

confidence: 99%

“…AM offers also significant advantages due to its short lead times and great geometrical freedom. This advantage makes AM the natural prosecution of TO processes [5,6].…”

Section: Introductionmentioning

confidence: 99%

Design and Production of Innovative Turbomachinery Components via Topology Optimization and Additive Manufacturing

Meli

Rindi

Ridolfi

et al. 2019

International Journal of Rotating Machinery

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The present paper proposes a methodology to design and manufacture optimized turbomachinery components by leveraging the potential of Topology Optimization (TO) and Additive Manufacturing (AM). The method envisages the use of TO to define the best configuration of the rotoric components in terms of both static and dynamic behavior with a resultant reduction of overall weight. Eventually, the topology-optimized component is manufactured by using appropriate materials that can guarantee valid mechanical performances. The proposed strategy has been applied to a 2D impeller used for centrifugal compressors to prove the effectiveness of a TO+AM-based approach. Although this approach has never been extensively used before to centrifugal compressors and expanders, its application on rotor and stator components might unlock several benefits: tuning the natural frequencies, a reduction in the stress level, and a lighter weight of the rotating part. These objectives can be reached alone or in combination, performing a single analysis or a multiple analyses optimization. Finally, the introduction of AM technologies as standard manufacturing resources could bring sensible benefits with respect to the time to production and availability of components. Such aspects are essential in the Oil and Gas context, when dealing with new projects but also for service operations.

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Designing for Additive Manufacturing: Lightweighting Through Topology Optimization Enables Lunar Spacecraft

Cited by 75 publications

References 8 publications

A Design for Qualification Framework for the Development of Additive Manufacturing Components—A Case Study from the Space Industry

A Design for Qualification Framework for the Development of Additive Manufacturing Components—A Case Study from the Space Industry

Design and Optimization of Graded Cellular Structures With Triply Periodic Level Surface-Based Topological Shapes

Design and Production of Innovative Turbomachinery Components via Topology Optimization and Additive Manufacturing

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