This study focused on the potential of topology optimization (TO) for metallic tertiary structures of spacecrafts produced by the additive manufacturing (AM) technique laser powder bed fusion. First, a screening of existing conventionally manufactured products was carried out to evaluate the benefits of a redesign concerning product performance and the associated economic impact. As a result of the study, the most suitable demonstrator was selected. This reference structure was redesigned by TO taking into consideration the AM process constraints. Another major aim of this work was to evaluate the possibilities and challenges of AM (accuracies, surface quality, process parameters, postmachining, and mechanical properties) in addition to the redesign process. A comprehensive approach was implemented including detailed analysis of the powder, mechanical properties, in-process parameters, and nondestructive inspection (NDI). All measured values were used for a back loop to the design process, thereby providing a final robust redesign. Finally, the fine-tuned demonstrator was built up in an iterative process. The parts were tested under representative conditions for the application to verify the performance. The demonstrator qualification test campaign contained thermal cycling, vibration testing, static load testing, and NDI. Thus, an improvement in technology readiness level up to “near flight qualified” was reached.

中文翻译：

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拓扑优化航天器结构增材制造的潜力和挑战

这项研究的重点是拓扑优化 (TO) 对通过增材制造 (AM) 技术激光粉末床融合生产的航天器金属三级结构的潜力。首先，对现有的传统制造产品进行了筛选，以评估重新设计对产品性能和相关经济影响的好处。作为研究的结果，选择了最合适的演示器。考虑到 AM 工艺限制，TO 重新设计了该参考结构。这项工作的另一个主要目的是除了重新设计过程之外，还评估 AM（精度、表面质量、工艺参数、后加工和机械性能）的可能性和挑战。实施了一种综合方法，包括对粉末进行详细分析，机械性能、过程参数和无损检测 (NDI)。所有测量值都用于设计过程的回环，从而提供最终稳健的重新设计。最后，在迭代过程中构建了经过微调的演示器。这些部件在具有代表性的应用条件下进行了测试，以验证性能。演示器资格测试活动包括热循环、振动测试、静态负载测试和 NDI。因此，达到了“接近飞行合格”的技术准备水平的提高。在具有代表性的应用条件下测试部件以验证性能。演示器资格测试活动包括热循环、振动测试、静态负载测试和 NDI。因此，达到了“接近飞行合格”的技术准备水平的提高。这些部件在具有代表性的应用条件下进行了测试，以验证性能。演示器资格测试活动包括热循环、振动测试、静态负载测试和 NDI。因此，达到了“接近飞行合格”的技术准备水平的提高。