Multidisciplinary Optimisation of Business Jet MED Hinge for Production by Additive Manufacturing

Additive Manufacturing (AM) using Powder Bed Fusion (PBF) processes is a novel and rapidly expanding manufacturing field which eliminates many conventional constraints from the manufacturing process. With the reduction of design inhibitors such as tool paths, AM becomes an ideal process for the fabrication of topology optimised (TO) structural designs. However, the relatively modern processes, particularly for metallic technologies, introduce additional design complexities which must be accounted for during optimisation in order to realise the maximum potential of the structural design. This work details the process from inception to delivery of the design optimisation of the MED (Main Exit Door) hinges for the Gulfstream G280 aircraft. Through several examples, a comparison of stress/mass and compliance topology optimisation for static and fatigue cycled structural parts with novel material properties and constraints will be evaluated. The report shows that significant mass reductions can be achieved even with heavily dimensionally constrained structures, subjected to high static and dynamic loadings. Finally the work assesses the suitability of AM PBF processes for the manufacture of TO components suitable for civil aerospace structural classes. The final summary highlights benefits not only from in service mass reduction, but also aesthetic considerations of visible structural parts and the combinatory benefits from the linked use of TO and AM.


The Author

Martin Muir
Jonathan Meyer
Alex Diskin
European Aeronautic Defence and Space Company (EADS)