One of the best ways to innovate is by combining two different technologies. I am going to show you an example. This ultra-lightweight metallic part is the result of the combination of two state of the art technologies: additive manufacturing and topology optimization.
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| A350 XWB Bracket (© Airbus S.A.S 2014) |
Topology optimization is a type of structural optimization which was discovered studying bones. Our bones are very lightweight because they have suffered an optimization through millions of years of evolution. On the one hand, holes have grown in low stressed areas. On the other hand, highly stressed areas have been reinforced. That is why our bones are lightweight and strong at the same time. There is bone only where it is needed. This has been studied and topology optimization software has been created. Now we can do the same as nature does in millions of years just in a couple of minutes. The result is a bionic design that is not only very lightweight but also very strong.
Topology optimization leads to designs that tend to be very complex and difficult to manufacture by conventional methods. Here is where additive manufacturing - also known as 3D printing - comes into play. Additive manufacturing is a technology that creates parts layer by layer. That means that almost any geometry can be manufactured by this method. In addition, there is practically no material waste and no tooling is required. However, it has to be said that surface roughness can be high, which reduces fatigue strength. And due to the manufacturing process, strength in the z-axis (perpendicular to the layers) will be lower than strength in the x- and y-axis (parallel to the layers). Therefore, it has to be taken into account that strength will be lower than expected.
In my opinion, the combination of these two great technologies has a lot of potential. It not only allows for weight reduction on aircraft and other vehicles, but also reduces material use, which can be very expensive for certain materials such as titanium.
What do you think?
