Additive Manufacturing (AM) is a manufacturing process through which a 3D component is produced by consecutively adding material. One of the most promising AM processes is SLM. In SLM a laser completely melts metallic powder particles together forming a 3D component. SLM is known for its freedom of manufacturing constraints allowing complex geometries and high material efficiency. Topology Optimisation (TO) is an optimisation type that calculates the optimal material distribution for a given problem. The combination of SLM with TO is being developed to create lightweight components. In this work, the whole development process, from optimisation to design, production and testing is addressed. Initially, an aircraft bracket topology was optimised to be produced by means of SLM. The TO solution was interpreted and designed for AM. During the interpretation and design process, a design methodology was defined in order to facilitate and make more accurate the TO solution design and make it ready for AM. After the optimised component was produced, metrological and mechanical tests were performed in order to validate the final design and the computer analysis. The optimised component showed considerable weight reduction with an increase of the factor of safety. The experimental tests revealed a good relation to the computer analysis evidencing, however, room for improvement, both in the computer model and the experimental tests

Additive manufacturing (AM) of polymer large parts is a technological research area with great growth potential if the main barriers to its implementation are successfully addressed. In this research, a review of large-format AM (LFAM) processes for polymers is presented, followed by market research concerning the identification of large-format polymer commercial printers. An overview was performed covering the current LFAM systems configurations and their control aspects. The design and modelling approaches related with the fabrication of polymer large parts by AM, and the materials currently being applied and under development, were described. Finally, a summary of LFAM applications with a focus in the Transportation, Academic, Construction and Energy sectors, was presented. The current main advances in the LFAM of polymers are linked with the possibility of producing large parts in a faster, cheaper, and reliable way. The market research analysis concerning results for all AM families involving polymer materials reveals that, currently, the material extrusion AM process family is potentially the most suitable to produce large parts, with a significant number of applications attesting its capability to produce such large-format components.