Design and development of topology-optimized aircraft bracket using additive manufacturing

In this work, the development of an aircraft bracket through the laser powder bed fusion (LPBF) additive manufacturing process is presented. The numerical model developed in this study is employed to predict thermal stresses and displacement of parts throughout the additive manufacturing process. To achieve a reduction in volume and, subsequently, the design space of the aircraft bracket, a geometry optimization technique - Topology Optimization is implemented. Additionally, the 3D Printed Titanium alloy aircraft bracket is subjected to industry-standard loading for analysis. In the simulation model, new elements are activated for every layer to simulate the recoating of filament powder, and the thermal gradient, thermal stress, and displacement of parts associated with each layer are computed. Notably, the topology optimization of the geometry demonstrates a considerable reduction in residual stress generation and a significant decrease in mass. The Solid Isotropic Material with Penalization (SIMP) method is employed in this study for topology optimization. The quality of the printed part is notably influenced by the geometry of the bracket. The findings of this study contribute to advancing the understanding of the interplay between topology optimization and additive manufacturing and highlight their collective potential for shaping the future of aerospace equipment fabrication. A volume percentage ranging from 50 to 75% of the original mass was allocated to guide the optimization process. The optimized geometry at 75% volume demonstrates the greatest reduction in residual stress generation compared to the original implant. This improvement in stress distribution is significant for aerospace brackets, as it allows for the development of lighter, stronger brackets manufactured more affordably using the Laser Powder Bed Fusion (LPBF) process compared to conventional processes.