GE Bracket Challenge

grabcad

The redesigned part has a weight of approximately 633g, which is significantly lighter than its original counterpart weighing around 2050g. However, there is no access to Finite Element Analysis (FEA) for strength/weight optimization or support evacuation. Two types of "laval" nozzles are depicted: one simple type in all internal cavities and a better revolved version in only one center cavity that needs optimization. As the interfaces are unknown, additive manufacturing may not be the most optimal solution for this part. The base could possibly be removed to produce the part via Metal Injection Molding (MIM), saving time and cost. The intention is to manufacture the part using Direct Metal Laser Sintering (DMLS) with an EOS machine, featuring large voids within the part that will allow non-sintered metal powder evacuation through provided holes by pumping fluid via an ultrasonic tank. Sintered supports are not expected to be necessary as the internal void shape tolerance is not critical.