Abstract

Today, the space industry is undergoing a period of significant technological advancement. Continuous progress in additive manufacturing technologies and the adoption of modern materials for 3D printing are driving this transformation. This trend has intensified competition among various space companies—both state-owned and private—each striving to introduce innovative and unique solutions. FlightControl Propulsion, a private space company in Ukraine, is one such example. This study focuses on the design of the power frame for a low-thrust liquid rocket engine. Power frames in rocket engines must withstand significant mechanical loads. The application of topology optimization and high-strength steels enables the development of compact and efficient power frames that are substantially lighter than traditional designs. Additive manufacturing not only significantly reduces the production time of various parts and assemblies but also offers nearly unlimited possibilities for creating complex geometric shapes. What was previously challenging or even impossible to manufacture using conventional methods has now become feasible. This work examines a component fabricated using Selective Laser Melting (SLM) technology. A structured algorithm for topology optimization is described, along with the fundamental principle of the SIMP (Solid Isotropic Material with Penalization) topology optimization method. Numerical modeling of the stress-strain state for the initial design variant is performed using the finite element method (FEM) in a computer-aided engineering (CAE) environment. A computational finite element mesh is generated, and the safety margins of the design are evaluated. Following topology optimization, the final design variant is determined, and numerical modeling of the stress-strain state is repeated for the optimized design. The final design is then prepared for manufacturing and subsequent experimental testing.