Introduction to Generative Design for Aerospace Applications

In recent years, machines have started to perform tasks once considered exclusive to humans. The rise of artificial intelligence has opened a debate on whether it can be adequate to perform routine tasks and tasks deemed creative. In this regard, milestones such as IBM’s Deep Blue defeating a chess champion and Watson competing on Jeopardy received broad interest from the media and the public. The rapid advance of technology and artificial intelligence is creating new opportunities for innovation in design. New generative design tools are being developed and improved, and while still requiring human oversight, they can create designs in which creativity is enhanced.

Although many definitions of creativity have been proposed, no universally accepted one exists. Traditionally, creativity is understood as the generation of ideas that are novel and useful. In this sense, it is possible to recognize creativity in various fields, such as architecture and industrial design. In the end, creativity is a key driver of innovation. This chapter traces the evolution of creativity from the early Oldowan stone tools to the Fiskars tools with their characteristic orange sleeves. The drivers of creativity and innovation, namely aesthetics, ergonomics, functionality, and identity, are introduced through examples that illustrate how these drivers have influenced the development of design throughout history.

In the last few years, there has been a growing concern about the evolution of the environment and, particularly, the impact that human activities have on it. One key challenge is to attain sustainable production processes, especially in industries such as aerospace and automotive. Generative design is a tool that can help optimize material usage. In transportation, this is key as it reduces fuel consumption and, thus, environmental impact. Generative design is linked to a manufacturing or production process, depending on the objective of creating a part or an assembly. Therefore, in the chapter, some of the most critical manufacturing processes relevant to generative design, such as additive manufacturing, machining, and assembly, are briefly presented.

Vast advances in technology emerged during the Third Industrial Revolution. Computers, transistors, and the Internet have fostered new technological developments such as artificial intelligence (AI). AI is increasing its role in various industries, particularly in design, where its influence continues to grow. In design, technology has helped evolve traditional manual drawings to computer-aided design, engineering, and manufacturing, and, currently, more advanced digital product development approaches. The design process can be amplified using big data and artificial intelligence technologies. Nowadays, data is pivotal in industry, and design can take advantage of the vast amounts of data and proper software for processing data. As technology evolves, the role of “machines” in the design process increases, opening a debate on whether technology will substitute the role of humans in the creative process. Ethical concerns and public acceptance are essential for the development of these new technologies, though their relevance may differ across sectors. In the case of aerospace, artificial intelligence has been used in multiple applications, and it is expected that, because of the coming advances in technologies, more applications can be developed in activities such as design.

Traditional design was mainly focused on functionality. Thus, designers had to define the geometry to meet objectives such as strength or thermal needs. Structural optimization techniques were developed to create efficient structures. The emergence of computational solutions has helped evolve structural optimization, with size, shape, and topology optimization already well-established methods that serve different needs, such as modifying dimensions, contours, and creating more complex geometries by optimizing material distribution within a design space, respectively. Topology optimization is an advanced method that helps generate innovative and lightweight structures. It is, therefore, a method more closely related to generative design. The method has been proven effective in various industries, including aerospace.

Generative design is a powerful tool that offers designers and engineers a new way to explore the design space through a collaborative human–machine process. An analogy can be drawn with the underlying philosophy of the Flatwriter machine proposed in 1970 by architect Yona Friedman to help users generate housing layouts and furniture arrangements. Today, generative design uses load cases, materials, constraints, manufacturing methods, and objectives to create multiple solutions rather than a single fixed outcome. The generated solutions are often unlikely to be designed by human designers and resemble biological structures. Generative design is gaining attention in various sectors, such as aerospace. This chapter presents several examples of generative design including aircraft bearing brackets, drone frames, and wing ribs, and examines the foundations of this methodology.

The chapter presents the concluding remarks of the book. The book aimed to introduce generative design to both specialized and non-specialized audiences, focusing on its application in aerospace. Generative design is closely linked with new creative design processes and a new manufacturing process. Specifically, the methodology is suited for additive manufacturing. In this sense, it can help obtain novel, lightweight designs that align with sustainable production objectives. Technological advances, such as big data, computing, and artificial intelligence, significantly enhance its capabilities. The suitability of this methodology in aerospace has been discussed by presenting several examples in previous chapters.