Design optimization application in accordance with product and process requirements

Structural optimization techniques are a well-known approach for improving product performances. Often, optimization procedures do not include manufacturing constraints arising from corporate technologies. This aspect becomes a disadvantage in the design review phase when the final product release is a trade-off between optimization results and 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 performance aeronautic seat structure having as mission profiles the SAE-AS Standard, 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 with 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 and 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.