Topology Optimization for Rudder Structures Considering Additive Manufacturing and Flutter Effects

This paper presents a multi-constraint topology optimization strategy for rudder structures, integrating additive manufacturing (AM)-related overhang angle and flutter-performance considerations. To the best of our knowledge, this is the first study to couple AM overhang control with mass center (flutter) steering in a single density-based formulation for flight control rudder structures. The approach incorporates constraints on structural volume fraction, overhang angle for AM, and mass center positioning to address multi-function design objectives—structural lightweighting, stiffness, aerodynamic stability, and manufacturability. A build-direction-aware projection filter and a smooth Heaviside mass center constraint are introduced to enforce these requirements during every optimization iteration. The resulting layout converges to a sandwich-type rudder with balanced mechanical performance and AM feasibility. Simulation results show that enforcing overhang constraints reduces support material usage by 46.9% and residual deformation by 14.2%, significantly enhancing AM feasibility. Additionally, introducing center-of-mass constraints improves flutter velocity from 3327 m s−1 to 3759 m s−1, indicating a 6.84% increase over conventional optimization and demonstrating improved dynamic stability. These simultaneous gains in manufacturability and aeroelastic safety, achieved without post-processing, underline the novelty and practical value of the proposed constraint set. The strategy thus offers a practical and efficient design method for high-performance, AM-friendly rudder structures with superior mechanical and aerodynamic characteristics, and it can be readily extended to other mission-critical AM components.