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Technical Documentation

Industrial Case Studies

Real-world DfAM case studies detailing topology optimization, weight reduction, lead time compression, and ROI.

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Lightweight Aerospace Jet Engine Bracket Redesign

Client Sector: Global Defense & Aerospace OEM

Material:Titanium Ti6Al4V Grade 5
Machine Fleet:EOS M 290

Engineering Challenge

Original CNC machined aluminum engine bracket was heavy (1.85 kg), required 6 separate sub-assembly fasteners, and had a 12-week forging lead time.

Legacy State:Legacy 6-Piece Assembly (1.85 kg)

Galactic DfAM Solution

Topology optimized single-piece generative titanium lattice structure produced via DMLS additive manufacturing with internal stress reduction annealing.

Optimized State:Galactic 3D Monolithic Titanium Bracket (0.70 kg)

Measured Quantitative Impact

62% Weight Reduction (1.85 kg down to 0.70 kg)
Zero assembly required (Monolithic consolidated part)
Lead time reduced from 12 weeks to 4 days
Passed 150% structural proof load vibration tests