0
Special Issue paper

Designing for Additive Manufacturing: Lightweighting Through Topology Optimization Enables Lunar Spacecraft

[+] Author and Article Information
Melissa E. Orme

Morf3D, Inc.,
821 N Nash Street,
El Segundo, CA 90245
e-mail: Melissa@morf3d.com

Michael Gschweitl

Ruag Space,
Zürich 8052, Switzerland
e-mail: michael.gschweitl@ruag.com

Michael Ferrari

Ruag Space,
Zürich 8052, Switzerland
e-mail: michael.ferrari@ruag.com

Ivan Madera

Morf3D, Inc.,
821 N Nash Street,
El Segundo, CA 90245
e-mail: ivan@morf3d.com

Franck Mouriaux

Ruag Space,
Zürich 8052, Switzerland
e-mail: franck.mouriaux@ruag.com

1Corresponding author.

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.

J. Mech. Des 139(10), 100905 (Aug 30, 2017) (6 pages) Paper No: MD-17-1121; doi: 10.1115/1.4037304 History: Received February 10, 2017; Revised July 10, 2017

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.

FIGURES IN THIS ARTICLE
<>
Copyright © 2017 by ASME
Your Session has timed out. Please sign back in to continue.

References

Wohlers, T. , 2016, “ Additive Manufacturing and 3D Printing State of the Industry: Wohlers Report,” Wohlers Associates, Fort Collins, CO.
Zhai, Y. , Lados, D. A. , and Lagoy, J. L. , 2014, “ Additive Manufacturing: Making Imagination the Major Limitation,” JOM, 66(5), pp. 808–816. [CrossRef]
XPrize, 2017, “ Google Lunar XPrize,” XPRIZE Foundation, Culver City, CA, accessed July 25, 2017, http://lunar.xprize.org/
Brandl, E. , Heckenberger, U. , Holzinger, V. , and Buchbinder, D. , 2012, “ Additive Manufactured AlSi10Mg Samples Using Selective Laser Melting (SLM): Microstructure, High Cycle Fatigue, and Fracture Behaviour,” Mater. Des., 34, pp. 159–169. [CrossRef]
Buchbinder, D. , Schleifenbaum, H. , Heidrich, S. , Meiners, W. , and Bültmann, J. , 2011, “ High Power Selective Laser Melting (HP SLM) of Aluminum Parts,” Phys. Proc., 12, pp. 271–278. [CrossRef]
Campbell, I. , Bourell, D. , and Gibson, I. , 2012, “ Additive Manufacturing: Rapid Prototyping Comes of Age,” Rapid Prototyping J., 18(4), pp. 255–258. [CrossRef]
Frazier, W. E. , 2014, “ Metal Additive Manufacturing: A Review,” J. Mater. Eng. Perform., 23(6), pp. 1917–1928. [CrossRef]
Bracket, D. , Ashcroft, I. , and Hague, R. , 2011, “ Topology Optimization for Additive Manufacturing,” Solid Freeform Fabrication Symposium (SFF), Austin, TX, Aug. 8–10, pp. 348–362. https://sffsymposium.engr.utexas.edu/Manuscripts/2011/2011-27-Brackett.pdf
Sigmund, O. , 2011, “ On the Usefulness of Non-Gradient Approaches in Topology Optimization,” Struct. Multidiscip. Optim., 43(5), pp. 589–596. [CrossRef]
Yan, C. , Hao, L. , Hussein, A. , Bubb, S. , Young, P. , and Raymont, D. , 2014, “ Evaluation of Light-Weight AlSi10Mg Periodic Cellular Lattice Structures Fabricated Via Direct Metal Laser Sintering,” J. Mater. Process. Technol, 214(4), pp. 856–864. [CrossRef]
Orme, M. E. , Gschweitl, M. , Vernon, R. , Ferrari, M. , Madera, I. J. , Yancey, R. , and Mouriaux, F. , 2016, “ A Demonstration of Additive Manufacturing as an Enabling Technology for Rapid Satellite Design and Fabrication,” International SAMPE Technical Conference, Long Beach, CA, May 23–26, pp. 1–17. https://www.researchgate.net/publication/306578773_A_DEMONSTRATION_OF_ADDITIVE_MANUFACTURING_AS_AN_ENABLING_TECHNOLOGY_FOR_RAPID_SATELLITE_DESIGN_AND_FABRICATION
Reiher, T. , and Koch, R. , 2015, “ FE-Optimization and Data Handling for Additive Manufacturing of Structural Parts,” Solid Freeform Fabrication Symposium (SFF), Austin, TX, Aug. 8–10, pp. 1092–1103. https://sffsymposium.engr.utexas.edu/sites/default/files/2015/2015-90-Reiher.pdf
Emmelmann, C. , Sander, P. K. , and Wycisk, E. , 2011–2012, “ Laser Additive Manufacturing and Bionics: Redefining Lightweight Design,” Phys. Procedia, 12, pp. 364–368. [CrossRef]

Figures

Grahic Jump Location
Fig. 1

Holistic process flow for additive manufacturing of high-quality, reliable metallic components

Grahic Jump Location
Fig. 2

LEROS engine support structure design baseline

Grahic Jump Location
Fig. 3

Preliminary exploration of design solutions within the design space (top image): ISO view, (bottom image): side view

Grahic Jump Location
Fig. 4

Identification of design tendencies encountered during exploratory topology optimization analysis; top image, top view of assembly; bottom image, side view of assembly

Grahic Jump Location
Fig. 5

Top image, top view of a topology optimized concept within the adapted design space (gray shaded region); bottom image, ISO view of topology results within the adapted design space (gray region)

Grahic Jump Location
Fig. 6

Final design space based on the evaluated concept to split the structure in order to allow printing in EOS M290. Individual design volumes of legs and hub connected at determined locations of the split.

Grahic Jump Location
Fig. 7

Rendering of the complete assembly of four identical legs and one hub that are joined by close tolerance shear bolts

Grahic Jump Location
Fig. 8

Separate components: top, hub; bottom, one of four identical legs

Grahic Jump Location
Fig. 9

Realization of connections: RBE–BUSH–BAR (6×)

Grahic Jump Location
Fig. 10

Results of the FEM analysis: stress plot of the complete engine mount structure subjected to (x/y) excitation

Grahic Jump Location
Fig. 11

Results of the FEM analysis: stress plot of the complete engine mount structure subjected to Z excitation

Grahic Jump Location
Fig. 12

Photograph depicting three build plates with the entire LEROS engine mount assembly components and their respective in-process coupons

Grahic Jump Location
Fig. 13

Photograph illustrating assembled components with a mock-up of the LEROS Apogee engine

Tables

Errata

Discussions

Some tools below are only available to our subscribers or users with an online account.

Related Content

Customize your page view by dragging and repositioning the boxes below.

Related Journal Articles
Related eBook Content
Topic Collections

Sorry! You do not have access to this content. For assistance or to subscribe, please contact us:

  • TELEPHONE: 1-800-843-2763 (Toll-free in the USA)
  • EMAIL: asmedigitalcollection@asme.org
Sign In