The thin-walled reinforced structure is important for achieving structural lightweight in spacecraft. With the rapid development of additive manufacturing technology, large-size, thin-walled, stiffened structures with complex structural forms can be manufactured. However, topology optimization considering manufacturing constraints has always been difficult in this field. This paper proposes a design method for reinforced structures that enables control over structural connectivity based on the Moving Morphable Components (MMC) method, which uses reinforced components with explicit geometrical parameters as primitives for topology optimization. The proposed method solves the challenges of rapidly designing complex geometric reinforcements, forming clear force transfer paths, and effectively reduces the structural topology optimization challenges caused by process constraints associated with the arc start/quench process of wire arc additive manufacturing (WAAM). This method was used to design a core load-bearing structure of a large satellite, i.e., the 3.5-meter tank supporting structure, which was fabricated by the WAAM process for the first time in the spacecraft field. The structure passed the mechanical test and eventually achieved a weight reduction of 31.6%.
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