Generative design of a tailwheel for ultra-light aircrafts

This final project’s aim is to re-design a mechanical component, part of the tail-landing gear for an ultra light aircraft, in order to produce it with AdditiveManufacturing. The core activity is using a Generative Design software, Fusion 360by Autodesk, exploring how this new emerging tool can be positively introduced inthe design activity. A first, three dimensional CAD model was realized, startingfrom technical drawing provided by the customer, representing the whole landinggear. After, a reduced model was elaborated, keeping only essential components tothe generative simulation and removing the others. This way, at the same time, alower number of geometrical uncertainties was introduced and a lower computationcost was required for simulations. Limits and merits of the Generative Designtool has been investigated and understood, learning how to tune input simulationparameters and successfully introduce iterative patterns. Working this way it waspossibly to achieve meaningful results such as component consolidation, reductionof assembly components’ number, and a consistent mass reduction, around 70% ofthe original weight. A final model is then proposed, making clear how this result isonly the starting point of a more complex design activity requiring the presence,apart from the Generative Design tool, of a Topology Optimizer and a softwareproviding fatigue analysis, absent in Fusion