Aerospace Bracket Weight Reduction
Project Scope & Objectives
The client needed to reduce the weight of a critical structural bracket for a new satellite launch vehicle while maintaining absolute structural integrity under extreme G-forces.
Technical Hurdles
Traditional manufacturing (CNC) limited the geometric complexity. Any material removal needed to be precisely calculated to avoid stress concentration points.
Our Engineering Approach
We applied AI-driven topology optimization (Generative Design) to create an organic lattice structure. The final design was manufactured using Direct Metal Laser Sintering (DMLS) in Aerospace-grade Titanium.
Key Technologies Applied
Measurable Impact
Achieved a 45% reduction in mass. Reduced part count from 3 assembled components to a single monolithic part, eliminating fastener failure risks and saving $2M in lifetime fuel costs per launch unit.
- Optimized STEP Models
- FEA Stress Analysis Report
- Titanium Prototype Parts
- ASTM Inspection Certificate
The weight reduction achieved by the engineering team was beyond our initial expectations. The monolithic part design has significantly simplified our assembly chain.
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