Topology optimization and additive manufacturing of an optical housing for space applications

The design of an optical housing for laser telecommunication in space is improved by topology optimization. Different mechanical and thermal boundary conditions are considered while minimizing the overall weight of the housing. As a proof-of-concept study, a complex and lightweight housing is made by additive manufacturing with the aluminium silicon alloy AlSi40. Post processing steps include a thermal treatment, cleaning and a mechanical machining process. Final characterization tests include the evaluation of material characteristics by tensile tests, a computed tomography scan and a CMM measurement. The final shock and vibrational test is used to proof the performance of the housing for future space applications.