Altair > Case Studies > Leveraging Topology Optimization and Laser Additive Manufacturing for Lightweight Structures

Leveraging Topology Optimization and Laser Additive Manufacturing for Lightweight Structures

Technology Category

Sensors - Lidar & Lazer Scanners

Applicable Industries

Aerospace
Automotive

Applicable Functions

Product Research & Development

Use Cases

Additive Manufacturing
Rapid Prototyping

Services

System Integration
Training

About The Customer

The Laser Zentrum Nord (LZN) and the Technical University Hamburg-Harburg (TUHH) were the primary entities involved in the research project. LZN was founded in 2009 to support knowledge and technology transfer from fundamental research to industrial application. It works in close cooperation with the Institute of Laser and System Technologies (iLAS) of the Hamburg University of Technology (TUHH). The research project was also supported by funding from the BMBF (German Federal Ministry of Education and Research). Premium Aerotec (PAG), a supplier in the aerospace industry, served as the project’s industrial partner.

The Challenge

The Laser Zentrum Nord (LZN) and the Technical University Hamburg-Harburg (TUHH) were seeking ways to improve the design and optimization methods for components made with laser additive manufacturing methods. The challenge was to develop structures that are strong yet light, similar to naturally occurring biological structures like bones. The research project, TiLight, aimed to combine innovative design methods with new manufacturing capabilities to economically manufacture lightweight components from the material TiAl6V4, a high-strength titanium alloy. The aerospace industry was the primary focus of the project, where lighter components could lead to higher load capacity or range for aircraft. A standard retaining element in aircraft, a bracket, was selected as a test object for the project.

The Solution

The solution involved using Altair's HyperWorks, OptiStruct, and Simulation Driven Design Process. The TiAl6V4 material was taken into account, and a customized process chain for the laser additive method was developed. The optimization tool OptiStruct was used to create the fundamental optimized structure. These structures were then compared and adapted to biological examples from nature before a final numerical verification of the final geometry was performed. The HyperWorks Suite was used in the concept phase of component design, providing integrated solutions for modeling, analysis, optimization, visualization, reporting, and data management. The proposed design was then refined with a CAD tool and the final design was numerically verified with OptiStruct.

Operational Impact

The TiLight research project demonstrated the potential and advantages of combining topology optimization and laser additive manufacturing. A best practice process chain was developed, enabling the design of optimized models and geometries. These geometries, oriented on natural structures, helped tap the component’s full lightweight potential. The results also showed that the more or less restriction-free manufacturing capabilities of the laser additive process can only be fully exploited when using optimization tools and a development process specifically suited to this manufacturing method. The combination of optimization, the adaptation of biologic structures, and laser additive manufacturing provides significant economic and efficiency advantages, especially in areas such as aerospace, where lower weight is directly linked to product performance. The results of the TiLight project have found their way into industry and are being used by a variety of companies.

Quantitative Benefit