Altair Case Studies Maximizing Additive Manufacturing Potential with Design Optimization in Aerospace

	Maximizing Additive Manufacturing Potential with Design Optimization in Aerospace Altair

Maximizing Additive Manufacturing Potential with Design Optimization in Aerospace

Altair

Technology Category	Sensors - Infrared Sensors
Applicable Industries	Aerospace Life Sciences
Applicable Functions	Product Research & Development Quality Assurance
Use Cases	Additive Manufacturing Rapid Prototyping
Challenge	Thales Alenia Space, a European aerospace manufacturer, was keen to explore the potential of additive manufacturing (AM) for its space satellite development programs. The company wanted to investigate the weight-saving potential of AM when combined with design optimization techniques. The challenge was to find a way to use these techniques in conjunction with new manufacturing technology. Thales Alenia Space chose a satellite’s aluminium filter bracket as a test case for the study. The bracket required a unique combination of both structural loads from the components that it supports, as well as thermal loads from the airflow through the filters and the temperature extremes of travelling to space. The primary objective of the study was to use design optimization techniques to reduce the thermal compliance of the bracket, while also optimizing the component for weight and readying the final design for the additive manufacturing process. Read More
About Customer	Thales Alenia Space is a leading European aerospace manufacturer with a presence in France, Italy, Spain, Belgium, the UK, Germany, and Poland. The company designs, integrates, tests, operates, and delivers space systems for the defence, Earth observation, communication, navigation, and security markets. With around 7,500 employees around the world, Thales Alenia Space is at the forefront of the development, implementation, and industrialization of additive manufacturing in the aerospace industry. The company is constantly exploring new technologies and manufacturing processes to improve its products and services. Read More
Solution	Thales Alenia Space partnered with Altair ProductDesign due to Altair’s expertise in developing design optimization technologies and implementing them in the aerospace industry. Altair ProductDesign’s first step was to convert the existing models of the bracket to a format that could be used with HyperWorks’ OptiStruct structural analysis solver and combine the two models together to create a unique thermal-structural model. This allowed the effects of both sets of constraints to be explored in parallel. Once the new model was confirmed to be an accurate representation of the physical bracket, the team moved on to the design optimization stage. Using OptiStruct, the team set up the model and specified numerous constraints that the technology would have to adhere to in order to provide a satisfactory solution. The bracket was divided into sections of 'designable' and 'nondesignable' space. Using topology optimization techniques, OptiStruct suggested a new material efficient design that met the performance criteria while removing material from areas that did not positively affect the design. The suggested geometry was then interpreted into a layout that was more suitable for the AM process and converted to a manufacturable CAD model. Read More Log in to view content
Contents

Technology Category

Sensors - Infrared Sensors

Applicable Industries

Aerospace

Life Sciences

Applicable Functions

Product Research & Development

Quality Assurance

Use Cases

Additive Manufacturing

Rapid Prototyping

Challenge

Thales Alenia Space, a European aerospace manufacturer, was keen to explore the potential of additive manufacturing (AM) for its space satellite development programs. The company wanted to investigate the weight-saving potential of AM when combined with design optimization techniques. The challenge was to find a way to use these techniques in conjunction with new manufacturing technology. Thales Alenia Space chose a satellite’s aluminium filter bracket as a test case for the study. The bracket required a unique combination of both structural loads from the components that it supports, as well as thermal loads from the airflow through the filters and the temperature extremes of travelling to space. The primary objective of the study was to use design optimization techniques to reduce the thermal compliance of the bracket, while also optimizing the component for weight and readying the final design for the additive manufacturing process.

About Customer

Thales Alenia Space is a leading European aerospace manufacturer with a presence in France, Italy, Spain, Belgium, the UK, Germany, and Poland. The company designs, integrates, tests, operates, and delivers space systems for the defence, Earth observation, communication, navigation, and security markets. With around 7,500 employees around the world, Thales Alenia Space is at the forefront of the development, implementation, and industrialization of additive manufacturing in the aerospace industry. The company is constantly exploring new technologies and manufacturing processes to improve its products and services.

Solution

Thales Alenia Space partnered with Altair ProductDesign due to Altair’s expertise in developing design optimization technologies and implementing them in the aerospace industry. Altair ProductDesign’s first step was to convert the existing models of the bracket to a format that could be used with HyperWorks’ OptiStruct structural analysis solver and combine the two models together to create a unique thermal-structural model. This allowed the effects of both sets of constraints to be explored in parallel. Once the new model was confirmed to be an accurate representation of the physical bracket, the team moved on to the design optimization stage. Using OptiStruct, the team set up the model and specified numerous constraints that the technology would have to adhere to in order to provide a satisfactory solution. The bracket was divided into sections of 'designable' and 'nondesignable' space. Using topology optimization techniques, OptiStruct suggested a new material efficient design that met the performance criteria while removing material from areas that did not positively affect the design. The suggested geometry was then interpreted into a layout that was more suitable for the AM process and converted to a manufacturable CAD model.

Impact #1	The study successfully demonstrated the potential impact that additive manufacturing could have on Thales Alenia Space’s products when combined with design optimization techniques. The new design for the bracket achieved a 48% reduction in mass when compared to the baseline, far beyond the 15 – 20% reduction that Thales Alenia Space was trying to achieve. In addition, the thermal compliance of the filter bracket was successfully reduced while maintaining the same structural performance of the original, much heavier design. The collaboration between Altair and Thales Alenia Space has proved highly beneficial. The companies’ combined team of engineers are now taking the study further and exploring the potential performance and weight improvements could be achieved with the introduction of lattice structures within the bracket design.

Impact #1

The study successfully demonstrated the potential impact that additive manufacturing could have on Thales Alenia Space’s products when combined with design optimization techniques. The new design for the bracket achieved a 48% reduction in mass when compared to the baseline, far beyond the 15 – 20% reduction that Thales Alenia Space was trying to achieve. In addition, the thermal compliance of the filter bracket was successfully reduced while maintaining the same structural performance of the original, much heavier design. The collaboration between Altair and Thales Alenia Space has proved highly beneficial. The companies’ combined team of engineers are now taking the study further and exploring the potential performance and weight improvements could be achieved with the introduction of lattice structures within the bracket design.

Benefit #1	48% mass reduction in the bracket design
Benefit #2	Significant reduction in thermal compliance of the filter bracket

Benefit #1

48% mass reduction in the bracket design

Benefit #2

Significant reduction in thermal compliance of the filter bracket

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Overview

Maximizing Additive Manufacturing Potential with Design Optimization in Aerospace

Operational Impact

Quantitative Benefit