Optimization approach to aircraft wing design in subsonic flow regimes

Reducing aircraft weight is vital for improving operational efficiency and lowering fuel consumption. This study explores topological optimization (TO) for aircraft wings, focusing on material redistribution to achieve lightweight and structurally efficient designs. Traditional design methods, which rely on empirical rules and iterative heuristic adjustments, are inherently limited in their ability to systematically explore the full design space or guarantee optimal material utilization. TO overcomes these limitations by employing gradient-based algorithmic methods that mathematically determine the optimal material layout for a given set of boundary conditions and load cases. Using MATLAB (for airfoil coordinate generation), CREO Parametric (for 3D CAD modelling), ANSYS Fluent (for CFD analysis), and ANSYS Workbench (for static structural and topological optimization), an aluminium wing was optimized, resulting in a 41% weight reduction—from 1.23 kg to 0.72 kg—without compromising structural integrity. The findings demonstrate the potential for TO to enhance performance, reduce costs, and streamline material use in manufacturing. The integration of TO with aerodynamic analysis highlights its capability to redefine traditional design processes, paving the way for innovative solutions in aerospace engineering.