Fraunhofer Institute for High-Speed Dynamics, Ernst-Mach-Institut, EMIOptimization approaches for lightweight and robust structures
We help partners in defense, aerospace, and mobility to reduce weight, increase performance, and integrate functionality by applying simulation-driven design optimization – tailored for additive manufacturing and complex multiphysics requirements.
Design Freedom Meets Physical Constraints
Additive manufacturing offers unprecedented design freedom – enabling complex geometries and multifunctional structures that are difficult or impossible to realize through conventional manufacturing. This opens the door to higher-performing and more compact components, functional integration, and weight reduction across a range of applications.
At Fraunhofer EMI’s Additive Design & Manufacturing group, we specialize in multidisciplinary and topology optimization of safety-critical structures under complex loading scenarios. A key focus lies on nonlinear optimization approaches for strain-rate-sensitive loads such as crash, blast, and ballistic impact – where traditional linear assumptions fall short. Our goal: to deliver high-performance, lightweight, and robust components that meet real-world functional and physical requirements.
Our competencies in structural design optimization include:
- Multiphysics-based topology optimization
- AI-supported generative design workflows
- Optimization strategies for strain-rate-dependent dynamic loads
- Robust design methods including material failure modeling
- Integration of workflows into commercial software
These methods enable us to design structures that combine lightweight efficiency with mechanical robustness, even under nonlinear material behavior or unexpected overload conditions.
Application Example: Satellite Structures
In the ERNST nanosatellite mission, we applied multidisciplinary topology optimization to design an optical bench subject to thermal, mechanical, and vibrational requirements. The result: a weight-optimized structure meeting all performance constraints – supporting mission functionality while reducing launch mass.
Robustness Through Intelligent Optimization
Topology optimization often relies on idealized linear assumptions that ignore critical failure mechanisms such as plastic deformation or cracking. We address this by developing robust optimization algorithms that incorporate nonlinear material models and redundant load paths, improving failure resistance under unforeseen loading.
Partner With Us
We develop and implement our own optimization methodologies – from nonlinear FEM-based algorithms to robust, AI-supported workflows – and integrate them into commercial software tools and customized design environments. Combine our expertise in multi-physics design, additive manufacturing, and material modeling to realize high-performance structures tailored to your application. We look forward to designing the future with you.
