Project number
25507
Organization
Cummings Aerospace
Offering
ENGR498-S2025-F2025
Additive manufacturing and topological optimization offer the potential for accurate and efficient production of high-performance parts, but gaps remain. This project addressed those gaps by combining CAD modeling, structural analysis (Finite Element Analysis or FEA), and physical testing to develop a reliable method for evaluating and optimizing 3D-printed polymer parts.
In aerospace, a high strength-to-weight ratio is critical because it maximizes structural performance while minimizing weight, improving fuel efficiency and overall aircraft performance. The team developed a series of tests to determine the optimal combination of infill patterns, densities, and wall thicknesses for the highest strength-to-weight ratio. We identified the most critical mechanical properties to measure and selected the most relevant tests to evaluate them, including Young’s modulus, shear and strain moduli, permeability, failure modes, and energy absorption. This process will enable engineers to predict the mechanical properties of 3D- printed aerospace parts for an efficient and reliable design.
In aerospace, a high strength-to-weight ratio is critical because it maximizes structural performance while minimizing weight, improving fuel efficiency and overall aircraft performance. The team developed a series of tests to determine the optimal combination of infill patterns, densities, and wall thicknesses for the highest strength-to-weight ratio. We identified the most critical mechanical properties to measure and selected the most relevant tests to evaluate them, including Young’s modulus, shear and strain moduli, permeability, failure modes, and energy absorption. This process will enable engineers to predict the mechanical properties of 3D- printed aerospace parts for an efficient and reliable design.