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Topology Optimization Risk Reduction

The topology optimization method outlined herein provides convincing evidence to re-think the way aircraft structure is designed. Topology optimization is gaining popularity and requires some further development to document the effective use of this tool and to aid the engineer in producing quality designs. The benefits are numerous, including load path visualization, weight savings, increased systems design space, improved ballistic protection and fatigue resistance. These benefits offer a compelling incentive to employ this technology into the current design process to improve the performance of engineering products. Topology optimization is an enabler for lighter weight structure with no recurring cost increase and no disruption to manufacturing. A finite element analysis approach has been developed, documented and substantiated through static and fatigue testing. Trade studies have demonstrated that a fifteen percent weight reduction is feasible for under floor structure on the CH-47 Chinook airframe.