Topology Optimized Load-Bearing Airframe with Additive Manufacturing

The integration of new design and manufacturing technologies like Topology Optimization (TO) coupled with Additive Manufacturing (AM) have the potential to revolutionize the development and delivery of UAS systems for the U.S. Air Force, offering multiple key advantages. Design Freedom: Topology Optimization provides engineers freedom to create structures that are not constrained by traditional design practices. Instead of using predefined rib and spar layouts, designers can combine structural requirements based on load paths resulting in far more efficient designs. Manufacturability: Topology Optimization can also contribute to improved manufacturability by reducing structure joint locations through parts consolidation, making AM a viable mfg. methodology. Lightweight and Efficiency: Optimized structures result in lighter more efficient airframe designs extending range, loiter time, and improved fuel efficiency. TO for AM structures made using AM systems such as Laser Powder Bed Fusion has been proven by companies such as General Atomics Aeronautical Systems Inc. (GA-ASI) in building smaller aircraft structures, however GA-ASI has stated that TO AM composites is poised as a long term solution for large scale UAS aircraft structures.