Generative Topology Optimization & Fatigue Assessment for Aerospace Sub-frame Bracket
01. The Engineering Challenge
Existing CNC-milled aerospace avionics mounting bracket carried significant weight penalty while subjected to multi-axis random vibration and high static load spectrums during acceleration phases.
02. Technical Objective
Redistribute material utilizing generative topology optimization to cut component mass by >30% while retaining structural natural frequency above 250 Hz and ensuring infinite fatigue life under operating spectrum.
03. Topology Optimization Methodology
Coupled SIMP topology optimization with additive manufacturing overhang angle constraints, followed by organic B-rep reconstruction and high-cycle stress-life (S-N) finite element verification.
04. B-Rep CAD Reconstruction & Verification
Iterative numerical optimization eliminated non-load-bearing web mass and generated an organic biomimetic truss architecture with uniform stress distribution across mounting lugs.
36.8% Mass Reduction with Infinite Fatigue Safety Factor
Topology optimization with additive manufacturing constraints created a component that was significantly lighter yet structurally stiffer than its traditionally machined predecessor.