A
passenger aircraft seat frame is a structural compo- nent uniquely designed for each aircraft confi gura- tion. Typically, they are constructed from a single billet. But was there a better way to manufacture that could also reduce costs? Autodesk, a leader in 3-D design and engineer-
ing software, had been developing a diff erent way of designing using generative design software, which
automates design options based on specifi c criteria such as weight and strength to perfect and speed up the design process. T e company’s research led to a unique lattice-like structure, and they contacted Aristo-Cast (Almont, Michigan), an in- vestment caster with experience in prototyping and magnesium, to help carry out the design for an aerospace seat frame. T rough collaboration and sound casting principles, Aristo-Cast delivered fi nal castings in four weeks that reduced weight by more than half compared to other lightweight frames on the market. Because of the benefi ts to the end-user and potential for casting growth in other applications for lightweighting, the aerospace seat frame has been named this year’s Casting of the Year by AFS and Metal Casting Design & Purchasing magazine. Using the generatively designed model, Autodesk sought to take out as much
material as possible without aff ecting the strength requirements needed. T e result was a much lighter seat frame with material located only were needed. T e new shape was a perfect fi t for investment casting. “T e casting design showcases the ability to change lattice thicknesses to add strength where it is required,” noted one judge in the casting competition. “T is
concept can be used to tie sections of a casting together where strength is not so critical to reduce weight.” Autodesk originally started devel- oping its generative design software for 3-D printing of direct-to-metal parts. But metal printing is constrained by size, and the team began consider-
MEDIA RESOURCE Using the Actable App on your mobile device, scan this
page to see a photo gallery of the many great castings submitted to this year’s competition, or look online at our website at
www.metalcastingdesign.com.
May/Jun 2017 | METAL CASTING DESIGN & PURCHASING | 21
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