Structural Optimization of MicroMED Dust Analyzer

Abstract

This research work describes the structural optimization of the MicroMED Dust Analyzer, an Optical Particle Counter developed for the ESA ExoMars 2022 mission. Topology Optimization, a non-conventional design technique was adopted to obtain a lighter component, a valuable achievement for aerospace and space scientific instruments design. In particular, two solutions for the instrument optical bench were proposed and assessed relying on a classical finite element approach, comparing the improved performance with the current design. The optimization outcome proved the adopted design workflow robustness and provided promising results in view of a possible mechanical design enhancement of the MicroMED Dust Analyzer instrument. Indeed, a mass budget saving of about 55% of the considered design domain was achieved, and the dynamic behaviour of the optical bench was improved by up to 50% of the first natural frequency value. Finally, a mockup of the lightened optical bench was manufactured, and the redesign effectiveness was proven by comparing the numerical mechanical resonances with the ones obtained experimentally. An error smaller than 5% was found on the first natural frequency, validating the performed optimization approach.