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Maximizing Additive Manufacturing Potential with Design Optimization in Aerospace
Technology Category
- Sensors - Infrared Sensors
Applicable Industries
- Aerospace
- Life Sciences
Applicable Functions
- Product Research & Development
- Quality Assurance
Use Cases
- Additive Manufacturing
- Rapid Prototyping
The Challenge
Thales Alenia Space, a European aerospace manufacturer, was keen to explore the potential of additive manufacturing (AM) for its space satellite development programs. The company wanted to investigate the weight-saving potential of AM when combined with design optimization techniques. The challenge was to find a way to use these techniques in conjunction with new manufacturing technology. Thales Alenia Space chose a satellite’s aluminium filter bracket as a test case for the study. The bracket required a unique combination of both structural loads from the components that it supports, as well as thermal loads from the airflow through the filters and the temperature extremes of travelling to space. The primary objective of the study was to use design optimization techniques to reduce the thermal compliance of the bracket, while also optimizing the component for weight and readying the final design for the additive manufacturing process.
About The Customer
Thales Alenia Space is a leading European aerospace manufacturer with a presence in France, Italy, Spain, Belgium, the UK, Germany, and Poland. The company designs, integrates, tests, operates, and delivers space systems for the defence, Earth observation, communication, navigation, and security markets. With around 7,500 employees around the world, Thales Alenia Space is at the forefront of the development, implementation, and industrialization of additive manufacturing in the aerospace industry. The company is constantly exploring new technologies and manufacturing processes to improve its products and services.
The Solution
Thales Alenia Space partnered with Altair ProductDesign due to Altair’s expertise in developing design optimization technologies and implementing them in the aerospace industry. Altair ProductDesign’s first step was to convert the existing models of the bracket to a format that could be used with HyperWorks’ OptiStruct structural analysis solver and combine the two models together to create a unique thermal-structural model. This allowed the effects of both sets of constraints to be explored in parallel. Once the new model was confirmed to be an accurate representation of the physical bracket, the team moved on to the design optimization stage. Using OptiStruct, the team set up the model and specified numerous constraints that the technology would have to adhere to in order to provide a satisfactory solution. The bracket was divided into sections of 'designable' and 'nondesignable' space. Using topology optimization techniques, OptiStruct suggested a new material efficient design that met the performance criteria while removing material from areas that did not positively affect the design. The suggested geometry was then interpreted into a layout that was more suitable for the AM process and converted to a manufacturable CAD model.
Operational Impact
Quantitative Benefit
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