Design Methodologies for Additive Manufacturing of an Aircraft Engine Component

The aim of the thesis has been to develop a solid methodology to optimize complex aviation components according to Additive Manufacturing process. Different optimization techniques available in literature are analysed to choose the best one to be applied to specific case. It is clearly impossible to consider entire model connected to the object of optimization but considering boundary conditions in precise way is a necessity. For this reason, reduction has been developed and has been taken into account during the simulation of the real test case. For this thesis, special consideration has been done for redesign an aircraft component that can be lightened. The component has been studied following two strategies: as a thin surface and as a design space without any coverage capability, only in a second step this geometry has been modified by the insertion of a skin with coverage features. During redesign process, Additive Manufacturing constraint like minimum thickness of the wall, overhang angle in a way that part could be produced with less supports as well and tubes self-supported, have been considered. The developed methodology could be useful also for other kind of processes doing suitable accommodation.