Design optimization of a business aircraft seat considering static and dynamic certification loading and manufacturability

A conceptual design for a lightweight business aircraft seat was developed using topology optimization in a 2-stage approach to consider both the static and dynamic certification test requirements of the Canadian Aviation Regulations (CARs) Section 525.561 and 525.562, respectively. Preliminary optimization was performed using static load requirements, and the interpretation of the optimization results was done considering key manufacturability metrics to reduce the cost of manufacturing components when using traditional subtractive manufacturing methods. A series of explicit dynamic models was run to predict the behavior of the seat during 14g and 16g certification tests and to estimate the maximum loads which the anthropomorphic test device (ATD) applies to the seat structure. Peak seatbelt loads were estimated at 9060 N and 8955 N for the left and right sides, respectively, and the asymmetry of the loads can be attributed to the 10° yaw of the aircraft required by the 16g certification test. Topology optimization was used to refine the design at the component level and further reduce weight using the loads determined in the dynamic modeling. The final conceptual design was 32% lighter when compared with the baseline structural components, and key manufacturability cost metrics were reduced by 24%.