Bracketosaurus

Plenty of long, late night hours sculpting this bracket. I use Autodesk Fusion 360 to form the bracket. It also offers FEA simulation to guide the optimization process, of which I've made about 60 iterations over the last couple weeks. I've worked to keep the support structure to a minimum, which may compromise the weight goal but makes for an all together more cost effective design. The yellow model shows the surfaces under 45', when the bracket is oriented with the flat mount points at 45'. The added benefit of this orientation is the low print bed footprint, allowing for multiple brackets to be nested in a single run. The organic shape will aid in more evenly dispersing stress points but I should highlight that it is still important to follow basic moments of inertia principles. Thanks to Alcoa for posing such an interesting challenge.