Topology optimization (TO) has proven to be a capable design methodology for the realization of lightweight solutions that maximize structural stiffness or other design objectives. Due to its capability to be adapted to suit a wide range of objectives and constraints, both structural and non-structural, TO has been widely applied in all industries, including aerospace. The application of TO in secondary structures offers the scope for further weight savings and, therefore, this thesis investigates the employment of TO on a galley structure provided by Safran-Cabins. The galley structure is an essential equipment for the functioning of passenger aircrafts and hence, provides an ideal product, which once optimized could offer widespread weight saving.

The next generation of commercial aircraft require solutions that are lightweight and yet economic to manufacture. TO solutions are renowned for their complex architectures and frequent employment in conjunction with additive manufacturing. However, for products such as galleys, which are required to be manufactured in large quantities, complex manufacturing strategies are not economically feasible. Therefore, this thesis proposes a modularization strategy that can be used to augment the monolithic TO solution into an assembly of simpler and identical modules. The modular design strategy has proven to be a capable strategy to enhance manufacturability as well as reduce costs over the board and offers a unique opportunity to leverage the capabilities of TO for employment on a wider range of products.

To achieve the aforementioned goal, an image moment-based modularization strategy is investigated which treats the TO solutions as digital images and identifies positions of simple bar/beam modules within the image based on matching of the image moments. Through a detailed investigation, a fragment constrained bar matching strategy is developed. It is demonstrated that the proposed matching strategy is capable of identifying positions of bar/beam modules within TO solutions from the literature. Additionally, a post-processing strategy is developed to augment the obtained modules and their positions into simplified and assembled frame structures analogous to the underlying TO solution. The developed framework is employed on the topologically optimized galley, and its practical capabilities and limitations are identified, thus providing a foundational work to be further refined.