Lattice structures integration with conventional topology optimization

Additive manufacturing (AM) processes enable the production of functional parts with complex geometries, multi-materials as well as individualized mass production. Another significant benefit of AM is the ability to produce optimized geometries with near perfect strength to weight ratios. For several years now, the topology optimization techniques assist the designers in order to develop components that have a good material distribution in order to reduce the weight ensuring the request stiffness. Therefore, the topology optimization generates concepts based on the subtractive approach and usually these geometries require a further post processing in order to obtain a geometry "ready to produce" that represents a compromise between the topologic result and the manufacturing constraints. The advent of the AM opens new scenarios in terms of definition of innovative geometries that are not feasible with the conventional processes (such as lattice structures). In order to exploit the AM capabilities, new topology optimization tools are emerging that allow to define innovative concepts that could reach structural performance greater than the result obtainable with conventional topology optimization. In this paper the Authors have studied a new concept design and the performance improvement, of PIN installation equipment, used for thin-walled aerospace workpiece, in order to solve critical dimensioning issues, due to the overcoming of the allowable range tolerances (strain and displacement). Topology optimization has been applied in order to define a new concept design able to satisfy the functionality requirements. Moreover, it has been conducted a study to evaluate the possible advantages offered by the integration of the lattice structure in the topology design in order to improve the performance in terms of weight and structural characteristics.