Design of 3D Printed Aircraft Seat Structure using Latticing in combination with Topology Optimization and Generative Design

Abstract

The aviation industry is responsible for 2% of all human-induced CO2 emissions. According to Iata (a trade body), the number of air passengers is predicted to touch 16 billion by 2050. Minimizing weight is central in achieving an ideal balance between payload and range of an aircraft and consequently, low fuel consumption. For instance, in a Boeing 787, a 20% weight savings will result in 10 to 12% superior fuel efficiency. Besides reducing carbon footprint, aircraft performance improvements like better acceleration, higher structural strength and stiffness, and increased safety could also be achieved by lightweight design. In this research paper, we propound the design of an aircraft seat structure which can be fabricated from Polyetherimide resin by 3D Printing. The structure is designed using topology optimization, generative design, and latticing. The lattice structures are made and tested on nTopology TM. The seat’s ergonomics are evaluated on Catia V5. The seat design meets all functional requirements without compromising on passenger comfort. The design can be used for standard commercial jets, and the weight savings are predicted to reduce fuel consumption drastically, resulting in lower costs and lower emissions.

Generative design and analysis of a double-wishbone suspension assembly: a methodology for developing constraint oriented solutions for optimum material distribution

“…The generative design methodology on Autodesk Fusion 360 enables the development of organic designs, which are optimized to the limit as per the load paths (Zaimis et al , 2021). A generative study approaches the problem in a different way; it not only takes the design constraints into consideration but also develops the design based on the loads that the part must sustain, the material that the part has to be made of and the FOS desired as an end result (Noronha et al , 2021). The standard control arm plate which has been designed indicates several regions under low stresses, where material removal is tangible.…”

Passive mitigation of low-frequency vibration modes in lightweight structures based on a new generation of acoustic black holes

“…These constructions have a high load to weight ratio that is not only highly beneficial in the building sector but for transportation applications as well, since less mass to move translates into energy savings. Huge efforts are directed towards making the supporting frame of vehicles lighter, especially with the help of numerical methods such as topology optimization and generative design (e.g., for cars [2][3][4] and planes [5][6][7]). Topology optimization is a method aiming at reducing by a given amount the mass of a mechanical component under a specific load, while minimizing the mechanical stress in the component.…”

Design of a metal additive manufactured aircraft seat leg using topology optimization and part decomposition

“…The aerospace industry is constantly exploring lightweighting opportunities, with a particular focus on aircraft seat design (Gulavani et al, 2014;Hughes et al, 2014;Trivers et al, 2020;Noronha et al, 2021;Roper et al, 2021;Tzanakis et al, 2023). As mass savings are compounded across every seat in the aircraft, an approximately 55% reduction in seat frame mass could lead to fuel savings of up to US$200m and a reduction of up to 140,000 tons of carbon in the atmosphere over the 20year life of a fleet of 100 Airbus A380s (Autodesk, 2017).…”

“…Aircraft seat legs have been designed in the literature using finite element (FE) analysis approaches (Gulavani et al, 2014;Hughes et al, 2014;Tzanakis et al, 2023). Seat leg structural design has also been conducted with TO using a pseudo-force technique (Noronha et al, 2021) and based on structural airworthiness certification requirements (Trivers et al, 2020;Roper et al, 2021). Despite the increased design freedom possible with MAM and the potential for significant mass reductions from a system-level viewpoint, no studies have conducted rigorous TO-based design for an aircraft seat leg with MAM.…”

“…, 2023). Seat leg structural design has also been conducted with TO using a pseudo-force technique (Noronha et al. , 2021) and based on structural airworthiness certification requirements (Trivers et al.…”