Design optimization application in accordance with product and process requirements

Structural Optimization techniques are a well-known approach in order to improve Product Performances. Optimization procedures, many times, do not include manufacturing constraints arising from the Corporate technologies. This aspect becomes a disadvantage in the Design revue phase when the final Product release is a trade-off between the Optimization results and the Manufacturing constraints. This paper describes a specific new approach which considers product/process guidelines an input/output data in the optimization phase. The study case is represented by a high performances aeronautic seat structure having as mission profiles the SAE-AS Standards, in order to demonstrate occupant protection when a seat/occupant/restraint system is subjected to statically applied ultimate loads and to dynamic impact test conditions. The authors’ aim, in accordance to standards requirements, is to achieve a final design based on an optimized structural solution for the chosen process technologies taking into account the low volume production, typical attitude of the aeronautical industry. The presented study case offers the proper reference in order to extend this methodology to more complex structural applications.