Aircraft bracket case study

Figure 1: Topology Optimization of the bracket Bild vergrößern

Objectives
The main purpose of this case study was to demonstrate the potential of Laser Melting for the development of brackets for the aircraft industry. Therefore, a given bracket should be redesigned, technical and economic benefits should be analyzed.

Procedure

For this case study a bracket was considered that mounts the luggage compartment damper to the aircraft structure. Its geometry was designed with topology-optimization methods. Under consideration of design rules from the Direct Manufacturing Design Rules project, the bracket was further designed in order to stick to manufacturing constrains and to minimize post-process operations. The bracket was manufactured and tested with several different loading conditions in order to prove its functionality.

Figure 2: Bracket design with internal structures Bild vergrößern

Achievements

Generally, the case study proofed that additive manufacturing can provide great advantages for the fabrication of brackets. In this particular case, the following achievements could be obtained:

  • Weight reduction of -46.2% (16.13 g) compared to the milling part (29.98 g)
  • Manufacturing cost increase of 39.47% (92.19 €) compared to the milling part (66.11 €)
  • Lifetime cost reduction of -39.50% (511.57 €) compared to the milling part (845.57 €)
Figure 3: Testing of the manufactured bracket Bild vergrößern
H&H GmbH

The Company H&H GmbH – partner of the DMRC since 2013 – offers all the development services required to transform an idea into a series product. Thereby, H&H develops and builds prototypes and then simulates, tests and produces the idea that has taken shape in series volumes.

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