Redesigning Aerospace Components Using a Coupled Topology Optimization and Lattice Generation Approach

The aerospace industry consistently prioritizes researching optimization methods for reducing component weight, meeting structural and thermal requirements, and enhancing product quality and efficiency. This work explores a design method that combines topology optimization (TO) and lattice generation to redesign three components: a jet engine bracket, an airplane bearing bracket, and an optical instrument mounting structure to satisfy their various structural and thermal loading requirements. Redesign and optimization methods for aircraft components such as jet engines and airplane bearing brackets have led to promising results, however, these components only have structural loading requirements. Spacecraft components such as mounting structures for optical instruments are needed for any space observation mission. Due to launch loads and the harsh space environment, they experience multiphysics loading requirements, including extreme stiffness for optical pointing precision, thermal resistance, and structural stability. The combination of loads and constraints poses challenges for the sole utilization of a single method or tool for optimizing mounting structures. Although TO and lattice generation methods are commonly used to create lightweight and optimized designs, each method has its limitations. Highly topology-optimized components may fail at unexpected loads, and many lattice generation methods are limited in controlling their geometric parameters. Combining these two methods would aid in balancing their respective shortcomings, leading to an effectively optimized component. In this study, TO software is coupled with a unique bubble-mesh-based lattice generation method that allows for variation in the following three parameters: cell size/lattice density, strut intersection rounding, and strut diameter. This coupled design process led to final designs that met the essential loading requirements of each component with the following weight reductions: mounting structure: 81.8%, jet engine bracket: 62.4%, and airplane bearing bracket: 52.5%.