Design and additive manufacturing of a fatigue-critical aerospace part using topology optimization and L-PBF process

Additive Manufacturing (AM) is a new generation manufacturing method and AM is using digital CAD data directed to the machine to manufacture. AM is therefore regarded as a direct digital manufacturing method. This research work presents the methodology for designing critical aerospace parts used under fatigue conditions for AM. Selected fatigue critical aerospace part was topologically optimized then re-designed for manufacturability. With this optimization study, 45 % mass saving was obtained while mechanical requirements were satisfied. Manufacturing simulations for thermal distortions are covered and the optimized part was manufactured with laser powder bed fusion (L-PBF) and secondary operations were applied.