Topologically Optimized & 3D Printed Component on its Way to Space!

1. case study
Topologically Optimized & 3D Printed Component
on its Way to Space!
RUAG Space, Morf3D and Altair team to demonstrate Additive
Manufacturing (3D Printing of metallic parts) as an enabling
technology for smaller, lighter, cheaper and faster access to space. In
a current project for Surrey Satellite Technology LTD, SSTL, the
partnership triad validated an aggressive eight week end-to-end
timeline that includes concept development, design, optimization, 3D
printing, testing and verification of the SSTL technologymission.
Moreover, AM lends itself to topology optimization, in which the
optimum distribution of mass for prescribed loading conditions
results in an efficient lightweight design that may be customized for
performance such as frequency response. Depending on design
constraints, organically shaped, bionic designs often result that find
natural coupling withAdditive Manufacturing processes.
To illustrate the benefits achieved with topology optimization and
Additive Manufacturing, Figure 1. is a illustrates the original
unoptimized part whose attachment points consist of three
orthogonal planar surfaces. Figure 2. is a fully topologically optimized
structure and Figure 3. is a photograph of the topology optimized 3D
printed AlSi10Mg alloy camera bracket that possesses a non-intuitive
organic shape.
While both brackets possess the same attachment point geometry
and are designed to withstand the same loading conditions, the team
was able to achieve a 79% weight reduction for the topology
optimized part and significantlyincrease frequency performance.
key facts
• Attachedcamera: 550gr
• Designloads: accelerationof 120g
• Frequency: firstmode at 420Hz
• Duration: 8wks from conceptto full qualification
• Printed using DMLS technology - EOS M290
In collaboration
with:
www.morf3d.com | info@morf3d.com | 310.607.7708
Original part – 425gr (Ti64)
Fully optimized– 79% less weight
3D Printed – 89gr(AlSi10Mg)