3D printing Integration with Topology optimization for Innovative design and fabrication of Light Weight Aerospace Structures

Topology optimization (TO) and 3D printing are the precocious methodologies which are integrated to produce light-weight structures with supercilious performance within design constraints of the structures. This research article discusses, the TO approach is used to determine the aircraft landing door bracket's optimum shape & size under various loads. The complicated optimized shape, which is challenging to build through convectional manufacturing process, is then created using 3D printing technique. Since from many years TO &3D printing have been performed separately, hence integrating these two techniques brings symbiosis results of obtaining light weight and complex geometric components. This article focuses on topology optimized approach by considering overhang constraint to fabricate a light weight aircraft landing door bracket through metal 3D printing technique by Selective laser melting (SLM )process. Altair solid-thinking inspire and Optistruct solver are used for this work. This article mainly focuses on shape optimization, mass reduction and to produce light weight bracket by 3D printing where the mass is reduced by about 52.27% without compromising structural and functional performance of the bracket. The obtained results indicate that, when3D printing is taken into account, topology optimization is a viable way of minimizing product weight while retaining design standards.