Direct Metal Printing helps in reducing the aircraft bracket weight by 70% while meeting all functional requirements.
Challenges:
The conundrum of balancing the design of a part with the constraints of manufacturing has existed since the Industrial Revolution. Conventional manufacturing techniques have limited capabilities to realize complex geometries or organically shaped components a cost-effective way. This results often in components where functionality and performance are a trade-off.
The critical nature of weight
Since the beginning of motorized travel on land, air or sea, engineers have striven to balance the demands of weight vs. strength. The balancing act has become more critical in recent years with greater worldwide manufacturing competition, stricter energy conservation measures, escalating cost and delivery time pressures.
Weight is especially crucial for modern aircraft. Although a Boeing 737 weighs approximately 65 metric tons, eliminating only one pound in weight can generate savings of hundreds of thousands of dollars each year for airline companies. Spread that number out to include all aircraft worldwide and the savings are upwards of $10 million according to a GE Aircraft white paper.
Optimizing the design
For the GE Aircraft challenge, Frustum’s software for topology optimization provided the first steps in tackling critical weight vs. strength issues.
Topology optimization determines the most-efficient material layout to meet the exact performance requirements of a part. It takes into consideration the given space allowed, load conditions of the part and maximum stresses allowed in the material.
Frustum’s software automatically generates optimized geometries from existing CAD files. It creates material between the design features to make optimally stiff and lightweight structures. Smooth and blended surfaces reduce weight and minimize stress concentrations.
“Based on existing conventional part design, our software automatically produces optimized geometry for Additive Manufacturing, without needing to do any remodeling,” says Jesse Blankenship, CEO of Frustum.
Unlike parts manufactured by traditional CNC or casting methods, the complexity of the model generated by topology optimization is of no concern, as DMP handles extremely complex models as easily as simplistic ones. Complexity comes at no cost.
Solutions:
Frustum’s software took the original CAD file and performed the topology optimization in one step, delivering an STL file.
3D Systems provided manufacturing advice on the process, material specifications, the best build orientation to deliver optimal part properties, achievable tolerances, and identified potential risk for deformations. The part was built on a 3D Systems ProX™ DMP 320 system.
Now that 3D printing, especially Direct Metal Printing (DMP), has become a viable manufacturing alternative, the constraints imposed by traditional manufacturing have been very much removed. In response to this, software tools for Multi-Disciplinary Design Optimization are now emerging to deliver a convergence point. Topology optimization software is now capable of generating the most efficient designs for one-step manufacturing on the latest generation of DMP systems.
Benefits:
The completed part, designed by Frustum and DMP-manufactured by 3D Systems, passed all the load condition requirements specified by the GE challenge and stayed within the same footprint while reducing weight by a staggering 70 percent.
“This is the kind of project that should be a real eye-opener for automotive and aerospace companies, where reducing weight while providing the same or improved functionality is the lifeblood of their design, engineering and manufacturing operations,” says Cornelus.
Beyond the design and performance of the part itself, Cornelus points out that topology optimization teamed with DMP can often consolidate multi-part assemblies into a stronger single part, eliminating fasteners and connectors that are often the cause of failures.
Finally, there is the coveted advantage of speed. Production-grade parts in tough materials such as stainless steel, titanium and nickel superalloy can be turned around by 3D Systems in as little as two weeks to satisfy the ever-quickening pace in myriad industries.