Weight reduction of a mount for a red dot sight through topology optimization and additive manufacturing: A study of red dot sight mount weight optimization

Abstract

This thesis investigates weight reduction of a mount for a red dot sight through simulation driven design optimization and laser powder bed fusion (LPBF). The aim was to reduce mass while maintaining the required mechanical performance, functional interfaces, and sight alignment. The original and redesigned geometries were evaluated using CAD modelling and finite element analysis (FEA) in Abaqus. The simulations were used to study stress distribution, displacement, and load paths under recoil loading. Based on these results, the design was modified in SolidWorks through repeated iterations and then evaluated with respect to structural performance and manufacturability. Physical validation was performed using mechanical shock and mounted drop tests. Titanium and aluminium prototypes were tested with the same procedure, where visual inspection and reticle position movement were used to evaluate functional performance. The results showed that the redesigned mount could reduce weight while maintaining acceptable mechanical behaviour in the simulations. The manufacturability evaluation also showed that build orientation, support placement, post processing, and tolerance sensitive features such as holes and threads were important when adapting the design for LPBF.