Gabriele Bussotti
Evaluation of implicit design methods and optimization tools for aeronautical applications.
Rel. Andrea Tridello. Politecnico di Torino, Master of science program in Mechanical Engineering, 2025
Abstract
The increasing quest for lightweight, high-performance components in the aerospace industry is driving the adoption of advanced structural design and manufacturing techniques. This thesis investigates the integration of topology optimization and additive manufacturing (AM) with implicit modeling methods, focusing on their potential to improve the design process of aeronautical components. Conducted in collaboration with Avio Aero – a GE Aerospace business – the study compares two distinct optimization workflows: a traditional explicit modeling approach using Altair HyperWorks (OptiStruct), and an implicit modeling approach using nTopology. Emphasis is placed not only on the structural performance and weight reduction achieved in the optimized components, but also on the efficiency of the design process, including workflow automation, geometric smoothness, and post-processing effort.
The research includes two test cases: a simplified academic benchmark (a loaded and constrained plate with holes) and a real industrial component (GE9X engine inlet gearbox housing)
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