Low-cost, High Performance Part Design

One stainless steel part for the Extremely Large Telescope (ELT) has been designed using topology optimization during a collaboration between Demcon and K3D. In this design assessment, the question was, "how to make a product lighter, while keeping a certain stiffness?". The specific part is purposed to fine tune mirror positions for a laser system part of the ELT which searches for extrasolar planets. Its original weight is 4.0kg, which made it highly inconvenient to mount this part and expensive for milling. The result after two design iterations is a more natural shape that could be produced by 3D printing, with a weight of 0.9kg and the ability to sustain its stiffness and strength. The part became almost a factor 3 cheaper to produce.