Multi-Material Topology Optimization for Conceptual-Level Aircraft Seat Design

As airlines seek to increase flight capacity and reduce operational costs, there is continued demand to reduce mass of conventional structures while maintaining strict safety standards and certification requirements. While the industry looks to adopt advanced composite materials and manufacturing methods to achieve these goals, new design tools are required to further optimize for component shape, sizing, and material selection. This paper presents multi-material topology optimization as the ideal numerical design tool for these complex problems. First, an overview of classical topology optimization is provided, followed by the extensions to multi-material. Following this review is a practical case study for the conceptual design of an aircraft passenger seat. This problem focuses on the study of single and multi-material designs and investigates the potential use of fiber reinforced polymers alongside conventional aluminum structures. Designs are discussed and compared with preliminary considerations of performance, cost, and design interpretation.