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Structural Design Optimization for CFRP in a Personal Aerial Vehicle

Increased urban expansion in recent years has uncovered an inefficiency in mid-range travel. Urban Air Mobility (UAM) aims to address this gap using hybrid and full-electric Personal Air Vehicles (PAVs) as a source of accessible, on-demand transportation. To achieve success with PAVs, reduction of mass is imperative due to the current battery capacity constraints. Many VTOL (Vertical Takeoff and Landing) PAV designs use multi-propulsor configurations which fix propulsor assemblies away from the main airframe using cantilevered boom structures. Booms must be lightweight to ensure aircraft efficiency but meet the structural requirements. This can be achieved using advanced materials such as Carbon Fibre Reinforced Polymers (CFRPs) paired with advanced design tools such as composite laminate optimization. Presently, existing literature in UAM design is focused on conceptual design optimization with high-level structural considerations for only conventional materials, which leaves significant weight savings unrealized. This work addresses this knowledge gap by presenting a detailed structural optimization methodology for PAV propulsor boom design applied to a PAV concept created in collaboration with Queen’s University, Konkuk University, and KCTECH. A comparison between the proposed design and a conventional design, with aluminum and standard optimization methodologies, shows a mass reduction of 74.6% using the advanced optimization approach.