Reducing the mass of an aircraft structure is not simply a question of replacing one material with another. The geometry, loads and manufacturing process all need to be considered together.

This demonstrator rethinks an aircraft door hinge using a hybrid structure combining aluminium interfaces with robotically wound carbon fibre. Topology optimisation first identifies where material is actually needed to withstand the component's demanding load conditions. The design is then adapted to the constraints of Gradel Robotic Additive Manufacturing (GRAM), ensuring that the optimised geometry can also be manufactured through controlled carbon-fibre winding. 

Testing plays an important role in the process. Results from the first prototype were used to refine the numerical model and feed a second design iteration, allowing stiffness, mass and winding geometry to be optimised together.

The latest prototype weighs 7.6 kg, almost 2 kg less than the original 9.5 kg aluminium component. Numerical analyses have been carried out across the required load conditions, while physical validation of the new prototype continues. Beyond one aircraft hinge, the demonstrator shows how topology optimisation and robotic composite manufacturing can work together to reduce material and weight while keeping manufacturability and structural requirements at the heart of the design.