Aerospace Bracket

Project Overview

This project involved designing a structural bracket for a CubeSat payload mounting application. Starting from a solid billet, topology optimisation in ANSYS was used to remove material from low-stress regions while maintaining stiffness and fatigue life under launch loading conditions. The final geometry was validated with a full non-linear FEA analysis and prepared for additive manufacturing.

Key Highlights

• 40% weight reduction over the baseline solid billet design
• Topology optimisation run in ANSYS with 3g launch load envelope
• Full non-linear static and fatigue FEA validation performed
• Design prepared for selective laser sintering (SLS) in Ti-6Al-4V
• Factor of safety > 2.0 maintained across all critical cross-sections