Optimization and optimum design are key words in relation to Additive Manufacturing (AM) and it is often identified as where AM has the largest potential. Topological optimization is a method used to create designs which satisfy a finite number of criteria; hence an optimum design is always a trade-off between several different requirements - e.g. loadings, material, weight, manufacturability, dimensions and tolerances. This means an optimum design is achieved when all the weighted requirement parameters are balanced within their respective acceptable ranges. GKN Additive, Autodesk and The University of Sheffield have carried out an investigation to validate a series of software packages for topological optimization and their structural analysis predictions. Redesigning an existing GKN Aerospace part, an Elevator Hinge Bracket from an aircraft tail, the results were prepared for AM before the parts were printed and post processed ready for loading onto a test rig. Within this practical experiment the upfront planning of the manufacturing stages was carefully considered and simulation of the builds carried out to help ensure that single production parts were successfully made. Despite this many lessons were learnt the hard way and can be shared so that a more robust process for additive manufacturing optimization is developed.
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