Hybridization of generative design and TPMS lattices: A statistical approach for lightweight aeronautical components

In the aerospace industry, reducing component mass without compromising mechanical performance is essential. Generative Design (GD), coupled with the geometric freedom of Additive Manufacturing (AM) and lattice structures, enables lightweight, high-strength geometries. However, lattice parameters are often selected empirically, lacking robust statistical analysis. This study addresses this gap by evaluating the mechanical response of lattice specimens across varying cell topologies, strut diameters, and materials using static Finite Element Analysis (FEA). Through Analysis of Variance (ANOVA) and multi-objective optimization, the ideal structural compromise was identified. Results demonstrated that the Gyroid structure, manufactured in AlSi10Mg with a 3 mm thickness, yields the best overall performance. To validate this methodology, a hybrid aeronautical bracket (combining a generative shell with a lattice infill) was virtually tested under operational boundary conditions. The optimized component achieved a 65.5% mass reduction compared to the original solid design for conventional manufacturing. Ultimately, the proposed hybrid approach maintains structural safety and demonstrates economic viability for AM.