Lattice-Infilled Wing Design with Metallic and Composite Skins Using Additive Manufacturing: A Comparative Study with Traditional Spar-Rib Structures

This study explores the potential of lattice-infilled structures as a lightweight alternative to conventional aerospace designs, focusing on their application in drone wings. Leveraging additive manufacturing capabilities, the research investigates metallic and hybrid (metal-composite) lattice-infilled wings, comparing them to traditional spar-rib structures through finite element analysis. A comprehensive design framework is developed using nTop and Ansys workbench software, along with Python-based iterative simulations to optimize lattice arrangements and sizes under applied loading conditions. The study evaluates different unit cell configurations to achieve the best stiffness-to-weight ratio, a crucial factor in aerospace weight reduction. The results demonstrate significant weight reduction, lower stress levels, and reduced wing tip-deflection in lattice structures compared to conventional designs. Additionally, the research examines the benefits of replacing metallic skin with composite materials for further weight reduction and performance enhancement. This innovative approach to wing design not only promises mechanical improvements and weight reduction but also offers potential environmental and economic benefits. The study highlights how such advancements in lightweight structures can contribute to reduced emissions and fuel savings in the aviation industry, underlining the importance of continued research in this field for future aerospace applications.