Research Article

Topology Optimization of an Aircraft Component Using Additive Manufacturing Constraints

Volume: 2026 Number: 17 June 1, 2026
TR EN

Topology Optimization of an Aircraft Component Using Additive Manufacturing Constraints

Abstract

This study applies topology optimization techniques to redesign an existing aircraft installation component, incorporating additive manufacturing constraints. Using ANSYS software, the research optimizes a part currently made of AL7050, comparing it with alternatives in Ti-6Al-4V (Ti64) and AlSi10Mg. The optimization process considers manufacturing and installation constraints while aiming to minimize compliance and reduce mass. Results show significant mass reductions across all materials, with AlSi10Mg achieving the most substantial improvement of 38.20% mass reduction and a minimum safety factor of 1.49. The study demonstrates the practical application of combining topology optimization and additive manufacturing in aerospace component design, highlighting opportunities for improved fuel efficiency and sustainable air transportation systems. The research also addresses challenges in integrating manufacturing constraints and material properties into the optimization process. Future work recommendations include exploring multi-physics optimization approaches and investigating the long-term performance of topology-optimized parts in aerospace applications.

Keywords

References

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  6. [6] Gibson I, Rosen D, Stucker B. Additive manufacturing technologies: 3D printing, rapid prototyping, and direct digital manufacturing. Springer; 2015.
  7. [7] Liu J, Gaynor AT, Chen S, Kang Z, Suresh K, Takezawa A, et al. Current and future trends in topology optimization for additive manufacturing. Structural and Multidisciplinary Optimization. 2018;57(6):2457-2483.
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Details

Primary Language

English

Subjects

Mechanical Engineering (Other)

Journal Section

Research Article

Publication Date

June 1, 2026

Submission Date

July 10, 2025

Acceptance Date

September 22, 2025

Published in Issue

Year 2026 Volume: 2026 Number: 17

APA
Totuk, O. H., Özkara, M., & Akar, S. (2026). Topology Optimization of an Aircraft Component Using Additive Manufacturing Constraints. Kocaeli Journal of Science and Engineering, 2026(17), 1-8. https://doi.org/10.34088/kojose.1739509
AMA
1.Totuk OH, Özkara M, Akar S. Topology Optimization of an Aircraft Component Using Additive Manufacturing Constraints. KOJOSE. 2026;2026(17):1-8. doi:10.34088/kojose.1739509
Chicago
Totuk, Onat Halis, Mustafa Özkara, and Samet Akar. 2026. “Topology Optimization of an Aircraft Component Using Additive Manufacturing Constraints”. Kocaeli Journal of Science and Engineering 2026 (17): 1-8. https://doi.org/10.34088/kojose.1739509.
EndNote
Totuk OH, Özkara M, Akar S (June 1, 2026) Topology Optimization of an Aircraft Component Using Additive Manufacturing Constraints. Kocaeli Journal of Science and Engineering 2026 17 1–8.
IEEE
[1]O. H. Totuk, M. Özkara, and S. Akar, “Topology Optimization of an Aircraft Component Using Additive Manufacturing Constraints”, KOJOSE, vol. 2026, no. 17, pp. 1–8, June 2026, doi: 10.34088/kojose.1739509.
ISNAD
Totuk, Onat Halis - Özkara, Mustafa - Akar, Samet. “Topology Optimization of an Aircraft Component Using Additive Manufacturing Constraints”. Kocaeli Journal of Science and Engineering 2026/17 (June 1, 2026): 1-8. https://doi.org/10.34088/kojose.1739509.
JAMA
1.Totuk OH, Özkara M, Akar S. Topology Optimization of an Aircraft Component Using Additive Manufacturing Constraints. KOJOSE. 2026;2026:1–8.
MLA
Totuk, Onat Halis, et al. “Topology Optimization of an Aircraft Component Using Additive Manufacturing Constraints”. Kocaeli Journal of Science and Engineering, vol. 2026, no. 17, June 2026, pp. 1-8, doi:10.34088/kojose.1739509.
Vancouver
1.Onat Halis Totuk, Mustafa Özkara, Samet Akar. Topology Optimization of an Aircraft Component Using Additive Manufacturing Constraints. KOJOSE. 2026 Jun. 1;2026(17):1-8. doi:10.34088/kojose.1739509