关键词: 增材制造, 选择性激光熔化, 拓扑优化, 面向AM设计

Abstract: Additive Manufacturing(AM) is a manufacturing process through which a 3D component is produced by consecutively addingmaterial.One of the most promising AM processes is SLM.In SLM a laser completely melts metallic powder particles togetherforming a 3D component.SLM is known for its freedom of manufacturing constraints allowing complex geometries and highmaterial efficiency.Topology Optimisation(TO) is an optimisation type that calculates the optimal material distribution for agiven problem.The combination of SLM with TO is being developed to create lightweight components.In this work,the whole development process,from optimisation to design,production and testing is addressed.Initially,an aircraft bracket topology wasoptimised to be produced by means of SLM.The TO solution was interpreted and designed for AM.During the interpretationand design process,a design methodology was defined in order to facilitate and make more accurate the TO solution design andmake it ready for AM.After the optimised component was produced,metrological and mechanical tests were performed in orderto validate the final design and the computer analysis.The optimised component showed considerable weight reduction with anincrease of the factor of safety.The experimental tests revealed a good relation to the computer analysis evidencing,however,room for improvement,both in the computer model and the experimental tests.

Key words: Additive Manufacturing(AM), Selective Laser Melting(SLM), Topology Optimisation(TO), design for AM