A Generalized Consolidated Topology Optimization and DfAM Design Approach and its Application for Assembly Design

— As additive manufacturing (AM) is widely adopted, there is a growing need for design for additive manufacturing (DfAM) tools and design methodologies. The increased design freedom allotted by AM has facilitated the adoption of topology optimization (TO) for AM. This presents an opportunity to introduce TO into DfAM best practices to improve assembly designs. A consolidated topology optimization and DfAM design approach for general assembly design is proposed. Unlike current DfAM methodologies, all critical aspects of assembly design are incorporated to ensure a fully optimized design. The efficacy of the consolidated design approach is demonstrated by its implementation for the redesign of a Bombardier business aircraft cockpit pedestal assembly. The manufacturing cost was reduced by 18%, satisfying the primary design objective. The installation cost will be greatly lowered due to a reduced assembly complexity: A major and minor part count and fastener count reduction of 17%, 89% and 56% was achieved. The current paper contributes to the applicability and efficacy of DfAM by outlining a generalized design procedure sufficiently complex and complete for industry level assembly design problems.