#FEA #CFD #Stress #Thermostructural #Additive Manufacturing

Our client from the additive manufacturing industry approached us to assist in the design of a motor housing and consult on the use of an appropriate aluminium alloy and lattice structures to improve its structural and heat dissipating performance and at the same time minimise its weight.

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We performed several analyses using non-linear static FEA to decide on an appropriate aluminium alloy that should be selected. After analysing the results and highlighting the highly stressed regions, we consulted on several potential lattice structure designs and topology optimisation techniques that should be employed, taking into consideration manufacturing limitations and cost requirements.

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In collaboration with our client, we selected three different variations and assessed them using non-linear static FEA and CFD to determine the most efficient design.

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The final design reduced the weight of the housing by 40%, without compromising its structural integrity and achieved a peak temperature reduction while in normal operation of 20%.