RuAviation

Enterprises within the United Aircraft Corporation (UAC) have commenced the manufacture of aircraft components employing bionic design – an approach that leverages solutions observed in nature to create structural elements within the aircraft’s airframe. Parts designed in this way differ from their traditional counterparts, featuring a branching and latticed structure reminiscent of plant structures or mammalian bones.

Employing these innovative technologies, the Sukhoi Design Bureau has developed an aluminium bracket for the Su-57 fighter, which is 10% lighter than a conventionally manufactured one, whilst its specific strength has increased by 20%, according to Rostec Group.

“The component bears more resemblance to a prehistoric animal’s bone than a part for a fifth-generation fighter. The new bracket is over 10% lighter than comparable parts produced using traditional techniques. Moreover, we have managed to achieve a 20% increase in its specific strength,” Rostec stated.

Bionic design, in conjunction with additive manufacturing, not only reduces component weight, but also cuts down on the consumption of costly, complex alloys and rare metals. Material savings can reach as much as 30% in some cases, which has a beneficial effect on the cost of the final product. Additive manufacturing, including 3D printing, enables the creation of complex structures that are impossible to realise using conventional manufacturing methods. This is particularly crucial for aircraft construction, where every kilogramme saved enhances the aircraft’s technical and economic performance.

The generative design methodology used in the creation of bionic components relies on computer-aided technologies that automate the design process, and design engineers can create algorithms that generate optimal solutions. Neural networks, trained on vast data sets, enable the system to independently identify dependencies and propose the most effective design options. This approach minimises human involvement in the intermediate stages of design, accelerating the development process.

SibNIIA conducts research into neural network algorithms in the development of bionic structures

One of the key advantages of bionic design is the ability to reduce component mass without compromising their strength – a feature of particular relevance to the aviation industry, where weight reduction directly impacts the aircraft’s aerodynamic characteristics, handling qualities, and cost-effectiveness. For example, the bracket developed by the Sukhoi Design Bureau is not only lighter but also stronger than its predecessors.

Additive manufacturing plays a critical role in the realisation of bionic design. Traditional manufacturing methods are unable to replicate complex structures, whereas 3D printing allows for the creation of parts with any thickness, curvature, and cavity, which is impossible when using standard CNC machine tools. For example, the All-Russian Scientific Research Institute of Aviation Materials (VIAM) has 3D-printed an aluminium bracket that is a quarter lighter than those produced using conventional methods. The process took just one night, whereas machining would have taken at least a week.

The Sukhoi Design Bureau is actively utilising additive manufacturing to create various components, including aircraft control elements. For example, to enhance ergonomics and ease of use, the control stick of the Su-57 fighter has been modified based on feedback from pilots and 3D-printed. In addition, a flight control pedal, as well as numerous parts for wind tunnel models of new aviation equipment, have been manufactured using layer-by-layer synthesis.

Bionic design and additive technology in modern aircraft engineering

Research in the field of bionic design and additive manufacturing is ongoing at research institutes across Russia. Employees of the SibNIA (Chaplygin Siberian Scientific Research Institute of Aviation) are exploring the application of genetic algorithms and neural networks for the design of bionic structures. For example, the institute has developed a topological optimisation algorithm that enables the creation of components with minimal mass and maximum rigidity. The technology has already been applied to optimise the pylon bracket of a flying laboratory based on the Yak-40 aircraft.

The introduction of bionic design and additive manufacturing into aircraft construction opens up new possibilities for reducing weight and increasing the strength of aircraft components. This not only improves the aircraft’s technical characteristics but also reduces manufacturing costs. Over time, such technologies may become standard practice in the aviation industry, gradually displacing traditional design and manufacturing methods.