Wire Arc Additive Manufacturing Process for Topologically Optimized Aeronautical Fixtures.

Area of Science:

• Materials Science and Engineering
• Mechanical Engineering
• Aerospace Engineering

Background:

• Additive manufacturing (AM) technologies for metallic materials are rapidly advancing.
• Design for additive manufacturing (DfAM) is crucial for leveraging AM's flexibility in creating complex geometries.
• DfAM facilitates material cost savings and promotes sustainable manufacturing practices.

Purpose of the Study:

• To develop a methodology for topological optimization of an aeronautical part.
• To adapt the optimized design for wire arc additive manufacturing (WAAM).
• To achieve lighter and more sustainable aeronautical tooling.

Main Methods:

• Topological optimization of an aeronautical component.
• Computer-aided manufacturing (CAM) for design adaptation.
• Wire arc additive manufacturing (WAAM) for tooling production.

Main Results:

• A methodology integrating topological optimization and CAM for WAAM was established.
• The process allows for the creation of complex geometries suitable for WAAM.
• The developed approach aims to reduce part weight and enhance manufacturing sustainability.

Conclusions:

• The presented methodology effectively bridges topological optimization with WAAM for aeronautical tooling.
• This integration supports the production of lighter, more resource-efficient aerospace components.
• The study highlights the potential of advanced design and manufacturing techniques for sustainable aerospace manufacturing.