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.