Lightweight Design and Mechanical Analysis of an Aircraft System Installation Bracket Fabricated by Laser Powder Bed Fusion

HAN Changjun; LI Heng; WANG Yi; LIU Hongtian; JIANG Ruizhe

doi:10.3969/j.issn.1674-6457.2025.11.010

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Journal of Netshape Forming Engineering ›› 2025, Vol. 17 ›› Issue (11) : 116-125. DOI: 10.3969/j.issn.1674-6457.2025.11.010

Intelligent Processing of Advanced Materials

Lightweight Design and Mechanical Analysis of an Aircraft System Installation Bracket Fabricated by Laser Powder Bed Fusion

HAN Changjun¹, LI Heng¹, WANG Yi¹, LIU Hongtian¹, JIANG Ruizhe^2,*

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Abstract

The work aims to propose a collaborative optimization method for laser additive manufacturing to achieve lightweight design of aircraft system installation brackets. A topology optimization model was developed by the variable density method (SIMP) with the optimization objective of maximizing static structural stiffness, while an integrated design framework was constructed by combining envelope optimization and shape optimization strategies. With a typical aircraft system installation bracket as the research object, systematic investigations including multi-load case finite element analysis, topology optimization, and geometric reconstruction were conducted. Laser Powder Bed Fusion (LPBF) process constraints were incorporated to achieve synergistic optimization between structural design and manufacturing processes. Finally, manufacturing and verification of the physical prototype were completed via the LPBF process. The initial bracket exhibited significant material redundancy and localized stress concentrations in the wall panels and overhanging regions, with a high safety factor of 6.3 indicating substantial weight reduction potential. The optimized structure achieved a 15.52% weight reduction while maintaining maximum stress and displacement at low levels of 34.25 MPa and 0.069 mm, respectively, well below the material yield strength, meeting installation accuracy requirements, with continuous load transfer paths and uniform stress distribution. The LPBF-formed components showed complete geometry and good surface quality, free from defects such as cracks, collapse, or warping, validating the good feasibility of the model. This research achieves significant weight reduction while ensuring structural strength and stiffness, providing a verifiable design framework for integrated lightweight and additive manufacturing design of aerospace load-bearing components.

Key words

laser powder bed fusion / aircraft bracket / lightweight design / topology optimization / envelope optimization

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HAN Changjun, LI Heng, WANG Yi, LIU Hongtian, JIANG Ruizhe. Lightweight Design and Mechanical Analysis of an Aircraft System Installation Bracket Fabricated by Laser Powder Bed Fusion[J]. Journal of Netshape Forming Engineering. 2025, 17(11): 116-125 https://doi.org/10.3969/j.issn.1674-6457.2025.11.010

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Funding

National Key R&D Program of China (2024YFB4608200); Fundamental Research Funds for the Central Universities (2024ZYGXZR079); Young Elite Scientists Sponsorship Program by CAST (2023QNRC001)