Innovative Hybrid Lattice Infilled Wing Design with Additive Manufacturing

Lightweight structures with a high stiffness-to-weight ratio are crucial for reducing aerospace weight. Lattice infilled structures have proven superior to conventional ones, offering better stiffness, strength, and lower weight. Additive manufacturing (AM) enables the production of these complex lattice structures, overcoming traditional manufacturing challenges. Composite materials, known for their exceptional properties, especially in different environmental and flight conditions, are increasingly replacing metallic parts. Combining metallic lattice structures with composite skins offers an optimal solution for aircraft wing design, improving performance and reducing weight. This study assesses the feasibility of metallic and hybrid (metal-composite) lattice infilled wing for a drone compared to traditional spar-rib design using finite element analysis. A comprehensive design framework for AM was developed using nTop tool. Iterative simulations were conducted to find the optimal type and size of lattice unit cells under level flight loading conditions. The process involved Python coding for iterative simulations, resulting in significant weight reduction, lower stress, and reduced wing tip deflection for lattice structures. A comparative study also examined the replacement of metallic skins with composite skins for further weight reduction and enhanced performance. The findings highlight the potential of innovative lightweight hybrid wing designs for aerospace applications.