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Article

Retrofitting of a High-Performance Aerospace Component via Topology Optimization and Additive Manufacturing

by
Jorge Crespo-Sánchez
1,*,
Claudia Solek
1,
Sergio Fuentes del Toro
2,
Ana M. Camacho
1 and
Alvaro Rodríguez-Prieto
1
1
Department of Manufacturing Engineering, Universidad Nacional de Educación a Distancia (UNED), C. Juan del Rosal, 12, 28040 Madrid, Spain
2
Department of Mechanical Engineering, Universidad Carlos III de Madrid, Avda. De la Universidad, 30, 28912 Leganés, Spain
*
Author to whom correspondence should be addressed.
Machines 2025, 13(8), 700; https://doi.org/10.3390/machines13080700
Submission received: 26 June 2025 / Revised: 28 July 2025 / Accepted: 5 August 2025 / Published: 8 August 2025

Abstract

This research presents a novel methodology for lightweighting and cost reduction of components with high structural demands by integrating advanced design and manufacturing techniques. Specifically, it combines topology optimization (TO) with additive manufacturing (AM), also known as 3D printing. Unlike conventional approaches, the proposed method first determines the optimal geometry using an artificially stiff material, and only then evaluates real materials for structural and manufacturing feasibility. This design-first, material-second strategy enables broader material screening and maximizes weight reduction without compromising performance. The proposed workflow is applied to the design of a turbofan air intake—an aeronautical component operating under supersonic conditions—addressing both structural integrity and manufacturing feasibility. Three materials from distinct classes are assessed: two metallic alloys (aluminum alloy 6061 and titanium alloy, Ti6Al4V) and a high-performance polymer (polyetheretherketone, PEEK). This last option is preliminarily discarded after being analyzed for this specific application. Finite element (FE) simulations are used to evaluate the mechanical behavior of the optimized geometries, including bird-strike conditions. Among the evaluated manufacturing techniques, Selective Laser Melting (SLM) is identified as the most suitable for the metallic materials selected, providing an effective balance between performance, manufacturability, and aerospace compliance. This study illustrates the potential of TO–AM synergy as a sustainable and efficient design approach for next-generation aerospace components. Simulation results demonstrate a weight reduction of up to 71% while preserving critical functional regions and maintaining structural integrity in Al 6061 and Ti6Al4V cases, under the diverse loading conditions typical of real flight scenarios, while PEEK remains an attractive option for uses where mechanical demands are less stringent.
Keywords: Selective Laser Melting; finite element simulation; Al 6061; Ti6Al4V; turbofan; 3D printing Selective Laser Melting; finite element simulation; Al 6061; Ti6Al4V; turbofan; 3D printing

Share and Cite

MDPI and ACS Style

Crespo-Sánchez, J.; Solek, C.; Toro, S.F.d.; Camacho, A.M.; Rodríguez-Prieto, A. Retrofitting of a High-Performance Aerospace Component via Topology Optimization and Additive Manufacturing. Machines 2025, 13, 700. https://doi.org/10.3390/machines13080700

AMA Style

Crespo-Sánchez J, Solek C, Toro SFd, Camacho AM, Rodríguez-Prieto A. Retrofitting of a High-Performance Aerospace Component via Topology Optimization and Additive Manufacturing. Machines. 2025; 13(8):700. https://doi.org/10.3390/machines13080700

Chicago/Turabian Style

Crespo-Sánchez, Jorge, Claudia Solek, Sergio Fuentes del Toro, Ana M. Camacho, and Alvaro Rodríguez-Prieto. 2025. "Retrofitting of a High-Performance Aerospace Component via Topology Optimization and Additive Manufacturing" Machines 13, no. 8: 700. https://doi.org/10.3390/machines13080700

APA Style

Crespo-Sánchez, J., Solek, C., Toro, S. F. d., Camacho, A. M., & Rodríguez-Prieto, A. (2025). Retrofitting of a High-Performance Aerospace Component via Topology Optimization and Additive Manufacturing. Machines, 13(8), 700. https://doi.org/10.3390/machines13080700

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