In the quest for sustainable aviation, researchers at the Netherlands Aerospace Centre (NLR) are pushing the boundaries of structural design with innovative topology optimization methods. Led by Wouter van den Brink, this groundbreaking research, recently published in the English-language journal *Engineering Proceedings*, explores how hybrid and multi-material approaches can revolutionize aircraft design, contributing to significant weight reductions and lower CO₂ emissions.
The aviation industry is under immense pressure to reduce its environmental footprint, with electric aircraft and structural weight savings emerging as key solutions. Van den Brink and his team have developed advanced topology optimization methods that cater to different scales of aircraft design, from individual components to full-scale aircraft. “Our goal is to identify optimal load paths and integrate them into multi-disciplinary design optimization (MDO),” van den Brink explains. “This approach allows us to explore novel structural designs for blended wing aircraft and other configurations, ultimately leading to lighter and more efficient aircraft.”
The research employs two primary methods. The first involves a preliminary design methodology that combines shell and solid elements in a 3D model using Abaqus software. By optimizing strain energy and weight under specific constraints, the team investigated various aircraft configurations, including blended wing designs. “We’ve made significant progress in translating these optimized designs into actual aerospace features, such as frames and Door-Surround Structures (DSS),” van den Brink notes.
The second method focuses on multi-material designs in conjunction with additive manufacturing technology. This approach presents opportunities for designing aircraft components with substantial weight-saving potential. The team explored multi-material topology optimization for a relevant aerospace wing component, revealing promising results. “The ability to manufacture multi-material metal parts via additive manufacturing opens up new possibilities for aircraft component design,” van den Brink adds.
The implications of this research extend beyond the aviation industry, with potential impacts on the broader energy sector. As the world transitions to cleaner energy sources, the demand for lightweight, efficient structures will only grow. The methods developed by van den Brink and his team could pave the way for innovative designs in various industries, from renewable energy to electric vehicles.
This study serves as a crucial first step towards lightweight, future electric aircraft design. By integrating innovative solutions, the aviation industry can make significant strides in reducing its climate impact. As van den Brink concludes, “Our findings highlight the potential to optimize battery-powered aircraft through innovative structural design, contributing to a potentially lower weight and further reductions in environmental impact.” With continued research and development, the future of sustainable aviation looks increasingly promising.