
Topology optimization of Lattice Structures for Morphing in Space Applications under Thermal and Mechanical Loads
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Embedding topology optimization with additive manufacturing constraints, enables the creation of optimal designs that are both functional and manufacturable. Our contribution focuses on designing lattice structures capable of morphing in response to thermal and mechanical loads, while ensuring compliance with stress constraints for space applications. We introduce a topology optimization framework tailored for the morphing of such structures, implemented within our proprietary finite element software, Morfeo. To achieve optimal designs with high performance, the optimization process integrates multiple design variables allowing for the inclusion of lattice structures [1, 2]. At mesoscale, we use dedicated design variables parameterizing the lattice substructure, while at macroscale, we implicitly represent the lattice with an equivalent material behaviour obtained through homogenization [1, 2]. We then formulate an optimization problem based on a hybrid method combining density and level-set XFEM approaches [1, 2]. The level-set ensures accurate surface and stress representations, while the density field allows hole nucleation during the optimization process. Additionally, stress constraints are integrated into the optimization process to maintain mechanical integrity under deformation. We apply our framework to a wing trailing edges such that it morphs to a target shape under deformation. Leveraging the flexibility of our optimization solver, we compare the performance of resulting structures based on different model hypotheses and material models, including isotropic and orthotropic lattice structures.