Design Optimisation and Manufacturing of an Anthropomorphic Humanoid Skull for Space Applications

• Published in: Journal of the Institution of Engineers (India) Series C 2024, Vol.105 (3), p.523-529
• Main Authors: Shaju, Tony M., Meshram, Ishan, Sivanandan, Dhanesh, Rao, G. Nagamalleswara, Krishnan Nair, Pradeep, Chaman, Joji J., Dev, D. Sam Dayala
• Format: Article
• Language: English
• Subjects: Aerospace Technology and Astronautics; Anthropomorphism; Design; Design optimization; Design parameters; Engineering; Humanoid; Indian space program; Industrial and Production Engineering; Laser sintering; Lattice design; Lattice parameters; Lattices; Manned space flight; Manufacturing; Mechanical Engineering; Original Contribution; Space flight; Space missions
• ISSN: 2250-0545; 2250-0553
• DOI: 10.1007/s40032-024-01041-3

In the quest to fathom unknown horizons and to know what is beyond our home planet Earth, mankind has been trying since long, to reach into the vacuum of deeper space and beyond. Nations all over the world are working vigorously on manned space missions, in the hope of making humankind a multiplanetary species. Indian Space Research Organisation (ISRO) has also been moving forward in similar lines and has elaborate plans to send humans to space. Before sending humans, a Half Humanoid which is being designed, developed and manufactured by ISRO is planned to make the first space travel from the Indian soil. As part of it, an anthropomorphic humanoid skull was designed and manufactured to be used in the Half Humanoid model. The method selected for the manufacturing of the skull was Metal Additive Manufacturing (AM) via the DMLS process (Direct Metal Laser Sintering). As the AM route is capable of manufacturing complex features, further mass reduction of the skull was achieved with the help of artificially intelligent incorporation of lattice structures into the design. The strength and stiffness requirements along with the lattice parameters were given as constraints during the design optimisation. An elaborate coupon study was conducted to understand the right philosophy of incorporating lattices structures to replace solid material from the structure. Insights from this study were used to select appropriate material volume on the structure where lattices would be inducted. The skull design that is incorporated with lattice structure was metal additive manufactured.