An end-to-end development approach for space flight qualified additive manufacturing (AM) components is presented and demonstrated with a case study consisting of a system of five large, light-weight, topologically optimized components that serve as an engine mount in SpaceIL's GLPX lunar landing craft that will participate in the Google Lunar XPrize challenge. The development approach includes a preliminary design exploration intended to save numerical effort in order to allow efficient adoption of topology optimization and additive manufacturing in industry. The approach also addresses additive manufacturing constraints, which are not included in the topology optimization algorithm, such as build orientation, overhangs, and the minimization of support structures in the design phase. Additive manufacturing is carried out on the topologically optimized designs with powder bed laser technology and rigorous testing, verification, and validation exercises complete the development process.
Designing for Additive Manufacturing: Lightweighting Through Topology Optimization Enables Lunar Spacecraft
Contributed by the Design for Manufacturing Committee of ASME for publication in the JOURNAL OF MECHANICAL DESIGN. Manuscript received February 10, 2017; final manuscript received July 10, 2017; published online August 30, 2017. Assoc. Editor: Carolyn Seepersad.
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Orme, M. E., Gschweitl, M., Ferrari, M., Madera, I., and Mouriaux, F. (August 30, 2017). "Designing for Additive Manufacturing: Lightweighting Through Topology Optimization Enables Lunar Spacecraft." ASME. J. Mech. Des. October 2017; 139(10): 100905. https://doi.org/10.1115/1.4037304
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