Design and Prototyping of Topology‐Optimized, Additively Manufactured Lightweight Components for Space Robotic Systems: A Case Study

This work presents the integrated application of topology optimization and additive manufacturing (AM) to develop lightweight structural components for space robotic systems, focusing on the deployment arm and rocker support of the Lunar Volatiles Mobile Instrumentation—Extended lunar rover. These components are subject to stringent performance requirements under reduced gravity, launch‐induced vibrations, and terrain‐induced loading. A level set‐based (LSB) topology optimization approach is applied to minimize structural compliance while adhering to constraints on mass, stress, symmetry, and manufacturability. Six mission‐specific load cases, including quasistatic surface operations and launch scenarios derived from Miles’ equation, are used to drive the design. The optimization achieves mass reductions of ≈50% for the deployment arm and the rocker support, while preserving mechanical integrity and functional interfaces. Post‐optimization validation through finite element analysis confirms that the optimized designs meet all structural performance criteria. Prototypes are fabricated via fused deposition modeling to assess manufacturability and assembly integration, paving the way for future metal AM using aerospace‐grade alloys. The results demonstrate a simulation‐driven workflow that applies LSB topology optimization with additive manufacturing constraints to mission‐specific load cases, integrating European Cooperation for Space Standardization compliant verification and manufacturability to develop structurally efficient rover suspension components.