An Additively Manufactured Self-Recovering Morphing Airfoil with Shape Memory Alloy Actuation

Morphing aerospace structures have attracted increasing attention as an efficient solution for improving aerodynamic efficiency by enabling continuous variation of wing geometry under different flight conditions. Among the available actuation technologies, Shape Memory Alloys (SMAs) are particularly attractive because of their high actuation force, compactness, and shape recovery capability. The aim of this work is to develop and numerically assess a lightweight morphing airfoil integrating SMA wire actuators within an additively manufactured lattice structure. A progressive numerical methodology has been adopted, starting from the analysis of a simplified section and extending to the complete morphing airfoil under representative aerodynamic loading. The simulations reproduced the complete actuation cycle, including mechanical deformation, unloading, thermal activation of the SMA wires, cooling, and structural recovery. The results demonstrate that the proposed architecture enables reversible shape adaptation while maintaining structural integrity throughout the loading cycle. Furthermore, the optimized design preserves its self-recovery capability under aerodynamic loads, confirming the effectiveness of combining lattice structures, SMA actuation, and Additive Manufacturing (AM). The proposed design methodology provides a promising framework for the development of lightweight adaptive aerospace structures with reduced mechanical complexity.