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Recent levels of structural integrity of components built in the Aeroswift high-speed laser powder bed fusion machine have led to the decision to produce a structural aircraft component through this technology. The Aeroswift machine is capable of building larger Ti6Al4V parts at a more rapid pace than current commercial laser metal powder bed fusion systems. As prototype component, the nose-wheel fork of the AHRLAC aircraft, which was conventionally machined in aluminum alloy 7050, was selected. This paper describes the design, topology optimisation and the manufacturing approach taken in this project.  Given the design space, loads, strength requirements and boundary conditions prescribed by the AHRLAC engineers, topology optimisation was performed on the nose-wheel fork to design a lightweight component for production in Ti6Al4V. Different topology optimisation software suites were used, to establish their capabilities and fit-for-purpose features. The optimised design and percentage of weight saving are presented. An assessment based on the experience with the different software suites is offered.

Topology optimisation of an aircraft nose-wheel fork for production in Ti6Al4V by the Aeroswift high-speed laser powder bed fusion machine