Optimisation of AM Components Using New Modelling Techniques

In the aerospace industry, there is an increasing need to reduce the weight of structural components in order to minimise carbon emissions and lower manufacturing costs. One technology that will allow us to  meet these requirements is additive manufacturing (AM). AM offers increased design flexibility, efficient material usage (powder material can be recycled) and the generation of parts and geometries that would otherwise be too difficult and/or expensive to machine or cast.

The full benefits of AM can only be realised when applied to the manufacturing of new topologically and structurally optimal components. Topology optimisation is a method for determining the optimal distribution of material for a given design space subject to certain restraints, loads and functionality requirements. Shape optimisation ensures that structures are suitably smooth, reducing peak stresses and therefore improving their fatigue performance. As part of on-going research into advanced manufacturing methods, TWI has developed numerical modelling capabilities that focus on topology and shape optimisation via the Abaqus Topology Optimization Module (ATOM), a software package from Dassault Systemès Simulia.

By coupling advanced numerical methods with AM technology, TWI aims to offer a stream-lined design-to-manufacturing process, allowing for the cost-effective manufacture of optimally designed components that can meet safety, reliability and environmental objectives.

In this presentation, a case study is presented that demonstrates the feasibility of this process on an aerospace-related component. The improved weight-savings and manufacturability of the component, whilst maintaining structural integrity, are compared to the initial design.