Case Study: Laser Zentrum Nord achieves lightweight, stiffer components with Altair HyperWorks (OptiStruct)

Combining Topology Optimization with Laser Additive Manufacturing Reveals New Potential for Lightweight Structures

Laser Zentrum Nord (LZN) set out to develop design and optimization methods that unlock the lightweight potential of laser additive manufacturing for aerospace components—specifically a TiAl6V4 aircraft bracket—by combining topology optimization with bio‑inspired design. To do this they partnered with Altair, using the HyperWorks suite and the OptiStruct optimization tool as the core of a simulation‑driven design process.

Altair supplied HyperWorks/OptiStruct to run topology optimization, support CAD remodelling and FE verification, and integrate the workflow for additive production; LZN then manufactured and validated the optimized brackets via selective laser melting. The result was lighter, stiffer, near‑net‑shape components, higher material efficiency and practical industry adoption—the process enables powder reuse up to 95% (versus up to 98% material waste for conventional milling), offers significant weight‑saving potential across fleets (civil aircraft can use up to 30,000 brackets), and has been incorporated into follow‑on projects and industrial use.

Laser Zentrum Nord

Jannis Kranz

Research Associate