Topology optimization applied to additive-manufactured hydrofoil wing components

This study investigates the development of hydrofoil components for an unmanned boat designed for control testing.Hydrofoils, characterized by their hydrodynamic shape, generate lift forces that elevate the boat above the water, enhancing its speed.Utilizing Fusion 360, a mechanism was designed to adjust the angle of attack of the hydrofoil wings.Subsequently, nTop and Eiger software were used to optimize and prepare these components for additive manufacturing (AM), with the primary objective being weight reduction.Material extrusion was selected as the preferred AM technology.The workflow within nTop was adapted for two materials: Onyx and carbon fiber-reinforced Onyx.Generative design techniques were applied, including field-driven design, lattice structures, and topology optimization (TO).Utilizing variable-thickness shells proved an efficient approach for reducing mass while preserving mechanical integrity.TO of the lever resulted in a significant reduction in mass.