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Nowadays, lightening of structural and mechanical parts of space vehicles while preserving the design
and functional requirements is one of the main challenges for space researches. It is obvious that
launching any additional mass of one-kilogram load to space costs approximately 20K Euros
according to the current tariff. Topology optimization is one of the most popular methods in structural
optimization as it does not only change the size and shape of a given design but also it changes the
material distribution while fulfilling the boundary conditions. In this study, an organic geometrical
modelling approach and a topology optimization for lightening of a satellite part that is expected to be
able to use in a spacecraft has been applied. All design approaches are taken into considerations for
Additive Manufacturing. A topology optimization tool of a commercial finite element software has
been used for an early optimized topology and an organic geometrical approaches have been
performed in order to satisfy the structural (strength and stiffness) and modal (natural frequency)
requirements. Biomimicry has been used in organic design. Tree-branch geometries have been used to
support the main bodies and increase the natural frequency. An elephant foot shape has been used on
the bracket contact surfaces to the ground to increase the stiffness of the body. The proposed design
exhibited very promising results, such as 45.2% weight reduction and 57.7% von-misses stresses
reduction when powder bed fusion process is to be used for manufacturing.
International Congress on 3D Printing (Additive Manufacturing) Technologies and Digital Industry
3D-PTC2019
M. Emin BADIR
E. SÖĞÜTKIRAN
Akın DAĞKOLU
Oğuzhan Yılmaz