Topology Optimization of an Additive Manufactured UAV Catapult Bracket Using SIMP and BESO Methods

Catapult systems enable Unmanned Aerial Vehicles (UAVs) to take off without runways and must therefore meet key requirements such as safety, reliability, portability, efficiency, and durability. These systems contain mechanically complex components that are subjected to substantial dynamic loads during operation. This study examines the topology optimization of a UAV catapult launch bracket using the SIMP and BESO methods to achieve a structurally efficient design compatible with additive manufacturing. The bracket was analyzed under axial compression and bending moments representative of launch conditions. SIMP was implemented through the Abaqus Tosca infrastructure, while the BESO optimization employed an Abaqus (2018)–Matlab (2024B) interface supported by automated Python (3.13.0) scripts. The optimized design achieved a 51% reduction in volume, with a 52% increase in maximum von Mises stress and an 8% increase in displacement, yet all stresses remained below the yield strength of AA7075. Manufacturability was assessed in terms of wall thickness, overhang angles, and support requirements, confirming suitability for SLM-based production. The results show that SIMP produces smoother material distribution, whereas BESO converges more quickly, and both approaches provide manufacturable and structurally reliable solutions for lightweight aerospace components.