Experimental validation of topology optimization and lattice design for additive manufacturing of a polymeric bracket

The thesis work is aimed at validating the results of design methods for additive manufacturing by structural FEM analysis including topology optimization and lattice design. The design methodology is applied using Solidthinking Inspire software to a polymeric copy of the ALCOA Bracket, a component used in the aircraft industry, with the objective of reducing part weight while fulfilling the design conditions. The design process involves a static linear analysis of the component for retrieving the stresses under specific design constraints and then performing topology optimization of part shape. The procedure is repeated separately on the same component by performing lattice design and optimization by using different combinations of lattice beam length and diameter. In order to validate the results of the design phase, several replicas of the component are fabricated by fused deposition modelling using an ABS filament. Finally, the replicas are tested on a tensile testing machine and the experimental results are compared to the design ones of Inspire software.