Fraunhofer-Gesellschaft
The ERNST project demonstrates how multidisciplinary design optimization was used to develop an optical bench for nanosatellites that meets thermal, mechanical, and vibration requirements. Through additive manufacturing and numerical optimization, a weight-optimized structure was created that fulfills all performance requirements while reducing launch mass.
General competencies in design optimization:
Beyond this project, we offer comprehensive expertise in the structural optimization of safety-critical components:
- Multiphysics-based topology optimization for complex load scenarios
- AI-driven generative design workflows
- Optimization strategies for strain-rate-dependent dynamic loads
- Robust design methods, including material failure modeling
- Integration of optimization processes into commercial software environments
These methods enable the development of lightweight structures that perform reliably even under extreme conditions such as crash, explosion, or ballistic impact.
Publications:
1. Hoschke, K., Kappe, K., Patil, S., Kilchert, S., Kim, J., Pfaff, A. (2024). Sustainability-Oriented Topology Optimization Towards a More Holistic Design for Additive Manufacturing. In: Klahn, C., Meboldt, M., Ferchow, J. (eds) Industrializing Additive Manufacturing. AMPA 2023. Springer Tracts in Additive Manufacturing. Springer, Cham. https://doi.org/10.1007/978-3-031-42983-5_6
2. Klaus Hoschke, Aron Pfaff, Konstantin Kappe, Philipp Hahn and Michael May (2024) Towards More Sustainable Aviation: Topology Optimization and Additive Manufacturing of a Cargo Door Latch Fitting https://doi.org/10.2514/6.2024-4642
3. Kappe, K.; Bihler, M.; Morawietz, K.; Hügenell, P.P.C.; Pfaff, A.; Hoschke, K. Design Concepts and Performance Characterization of Heat Pipe Wick Structures by LPBF Additive Manufacturing. Materials 2022, 15, 8930. https://doi.org/10.3390/ma15248930
4. Schimmerohn, Martin & Horch, Clemens & Busch, Stephan & Ledford, Noah & Schäfer, Konstantin & Maue, Thorsten & Weber, Mike & Kappe, Konstantin & Schäfer, Frank & Schweitzer, Caroline & Hoeffgen, Stefan & Paape, Andreas. (2022). ERNST: Demonstrating Advanced Infrared Detection from a 12U CubeSat.
5. Hoschke, Klaus & Kappe, Konstantin & Riedel, Werner & Hiermaier, Stefan. (2020). A Multimodal Approach for Automation of Mechanical Design. 10.1007/978-3-030-50460-1_17
6. Hoschke, Klaus & Kappe, Konstantin & Bierdel, Marius & Riedel, Werner & Hiermaier, Stefan. (2019). A topology optimization based design model for enhanced energy absorption and fail-safe behaviour.
Links:
Contact:
Konstantin Kappe, konstantin.kappe@emi.fraunhofer.de, +49 (761) 2714 – 587