Key principles.
FEA-driven
FEA optimizes mass distribution. Generative design.
Composite for metal
Carbon fiber composite for steel. Aluminum for steel.
Internal porosity
3D printed lattices replace solid sections.
Internal cavities
Hollow components vs solid where possible.
I-beam vs solid
I-beam efficient stiffness/mass. Tube hollow.
Carbon fiber
Composite for highest stiffness-to-mass.
FAQ
FEA finds optimal mass distribution for given loads. Generative design tools.
Carbon fiber 1.5 g/cm³ vs aluminum 2.7 g/cm³. ~50% lighter at equivalent stiffness.
Internal lattice structures replace solid. 30-70% mass reduction. Aerospace standard.
Lightweighting typically 30-100% cost premium. Per industry priority.
3D printing enables lattice. Composite layup specialty. Per process.
FEA + physical testing. Mass-stiffness-strength all verified.
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