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The study preliminaries for the production, research, and development push to the thrust of additive manufacturing (AM) components. The use of AM opens optimization of components with various techniques, topology optimization material choice optimizations, build freedom, etc. The study provided a more than 60% weight reduction of the General Electric G90 engine blocker door hinge bracket and better characteristics with topology optimization and use of a lighter and premium material Ti–6Al–4V alloy. The study showed maximum tension and compression results of 4.228e+06 and 6.726e+06 pa, respectively, to 3.062e+06 and 5.541e+06 pa, major principal stress from 4.925e+06 to −2.404e+06 pa to a lower degree from 3.597e+06 to −1.125e+06 pa in the topologically optimized design, respectively. While deformation results slightly upsized from 1.895e−05 to 2.774e−05 m, the factor of safety gets increased by a margin.

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Topology Optimization of Additively Manufactured Thrust Reverser Blocker Door Hinge Bracket for Aeronautical Applications

  • 会议论文

  • 发表日期：

    2026年

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  • Sukrit Kumar,
  • Anoushka Verma,
  • Eswara Krishna Mussada,
  • Swaroop Mallick,
  • Devesh Jaiswal

摘要

The study preliminaries for the production, research, and development push to the thrust of additive manufacturing (AM) components. The use of AM opens optimization of components with various techniques, topology optimization material choice optimizations, build freedom, etc. The study provided a more than 60% weight reduction of the General Electric G90 engine blocker door hinge bracket and better characteristics with topology optimization and use of a lighter and premium material Ti–6Al–4V alloy. The study showed maximum tension and compression results of 4.228e+06 and 6.726e+06 pa, respectively, to 3.062e+06 and 5.541e+06 pa, major principal stress from 4.925e+06 to −2.404e+06 pa to a lower degree from 3.597e+06 to −1.125e+06 pa in the topologically optimized design, respectively. While deformation results slightly upsized from 1.895e−05 to 2.774e−05 m, the factor of safety gets increased by a margin.