Topology optimization applied to additive-manufactured hydrofoil wing components

Abstract

This study investigates the development of hydrofoil components for an unmanned boat designed for control testing. Hydrofoils, characterized by their hydrodynamic shape, generate lift forces that elevate the boat above the water, enhancing its speed. Utilizing Fusion 360, a mechanism was designed to adjust the angle of attack of the hydrofoil wings. Subsequently, nTop and Eiger software were used to optimize and prepare these components for additive manufacturing (AM), with the primary objective being weight reduction. Material extrusion was selected as the preferred AM technology. The workflow within nTop was adapted for two materials: Onyx and carbon fiber-reinforced Onyx. Generative design techniques were applied, including field-driven design, lattice structures, and topology optimization (TO). Utilizing variable-thickness shells proved an efficient approach for reducing mass while preserving mechanical integrity. TO of the lever resulted in a significant reduction in mass.

The Heat Treatment Effects on the Microstructure, Hardness, and Sigma Phase Content of L-PBF SAE 316L Stainless Steel

“…Initially designed for prototyping purposes, additive manufacturing (AM) has evolved to enable the production of functional and structural components characterized by intricate geometries or customized structures featuring lightweight properties [1][2][3]. This way, it is possible to have significant personalization of the fabricated parts, which can be attractive for industries such as aerospace and biomedical since this method can produce near-net shape parts with complex geometries at no extra costs [4][5][6][7].…”