Metallic Additive Manufacturing (AM) technology can deliver breakthrough solutions to U.S. Navy air platform and weapon systems by drastically increasing performance and reducing weight. However, the current design and engineering tools cannot fully exploit the design freedom brought about by advanced AM processes. In addition, many existing topology optimization tools are unable to directly address key air platform performance metrics such as strength, fatigue, aerodynamics, shock, and vibration. To tackle these deficiencies, Adjoint Technologies proposes an innovative material and structural design software by extending a revolutionary bio-inspired topology optimization technique to metal additively manufactured air platform structures. Relevant AM design considerations will be directly integrated into the topology optimization including process-dependent material properties and geometric constraints to ensure build-ability and to accommodate powder removal. The tool, which will be capable of discovering complex, high performance structural configurations specifically adapted for additive manufacturing, will be demonstrated for the topology optimization on a benchmark naval air platform component.
Benefit: The anticipated benefits of the proposed effort include higher performance platforms and weapon systems as well as reduced procurement and sustainment costs for the Navy. These benefits are enabled by the topology optimization for additive manufacturing design tool we will develop. The topology optimization-based tool will provide engineers with the necessary capabilities to exploit the freedom of additive manufacturing processes while also ensuring the additive build-ability of design concepts. This capability is desirable across the entire 3D printing and additive manufacturing industry, which provides significant commercial opportunities. In defense applications, designers and manufacturers of systems serving the Navy and other branches of DoD can employ the technology in both the design of new platforms and the sustainment of existing weapons. Other industries, including automotive, biomedical, and consumer goods, are also adopting additive manufacturing processes and the proposed tools can be adapted for the design of a wide variety of components.
Keywords: Air Platform, Air Platform, 3D printing, additive manufacturing, structural design, design framework, topology optimization, Design Criteria
