At Autodesk University Las Vegas, the companies will present how product development and production of aircraft parts can become smarter, more efficient and more economical in the long term with the help of Autodesk technology. Two aircraft components are to be realized in the future using the generative design approach: Production of the further developed so-called bionic bulkhead will start shortly. Autodesk technology will also be used in the development work for the new version of the vertical stabilizer of the A320. Airbus is also planning to build a "production facility of the future" in Hamburg. The aircraft manufacturer is also relying on the generative design approach when planning the future-oriented factory and is pursuing the goal of creating an optimal, modern working environment for its employees for greater efficiency and productivity.

Bionic partition wall 2.0 goes into production

Airbus presented its first feasibility study with generative design back in 2015: a so-called bionic partition wall. This is a futuristic version of a partition wall that separates the passenger compartment from the aircraft's galley and supports the folding seats for the cabin crew.

Redesigned with the support of Autodesk, the partition is 45 percent lighter than conventional parts of this type, but just as strong - the weight savings also have a positive impact on the aircraft's_{carbon footprint}. Airbus estimates that the new design approach could save almost half a million tons of_CO2 per year if the element is incorporated into current orders for A320 aircraft.

After the originally desired production method using 3D metal printing was not possible due to various factors such as the material requirements in aviation, the team responsible investigated alternative manufacturing processes and opted for a mix of classic casting technology and 3D printing processes: Airbus first produces a 3D-printed mold made of plastic and then casts the component in an alloy that is already approved for flying.

The bionic partition 2.0 is just as stable and lightweight as its predecessor. "The adapted design makes the bionic component much easier to produce. The first prototype is already in the works and will hopefully be completed before the end of this year," says Bastian Schäfer, the designer at Airbus responsible for the cooperation with Autodesk. Thanks to the optimizations, the bionic partition wall 2.0 can even be produced at the same cost as the component currently in use, Airbus explained at Autodesk University.

A model of the vertical stabilizer of an A320 optimized with generative design. © Autodesk

"Tail fin" in a new design - Airbus tests new design options

Airbus also announced that it is already working on the optimization of another aircraft part - the vertical tail (colloquially known as the tail fin) of the A320. The function of an aircraft's vertical stabilizer is to provide directional stability and reduce aerodynamic inefficiencies that can be caused by lateral movement. Autodesk's generative design approach enables the development team to run through hundreds of design alternatives. These all meet the requirements for the vertical stabilizer in terms of stiffness, stability and mass, but at the same time offer advantages in terms of weight, which plays an important role in aviation.

Generative design supports the planning of a "production facility of the future" in Hamburg

Airbus is also planning to build a new production facility for the assembly of engines in Hamburg. The special feature: Encouraged by its positive experience with aircraft components and a promising pilot project, Airbus will rely on Autodesk's generative design approach when planning both the building and the work processes. Airbus' aim is to significantly speed up the assembly of engines with more efficient logistical processes and thus also increase employee productivity - in a production facility that can be flexibly adapted to the company's current and future requirements.

"Generative design enables us to develop a more sustainable architecture that better meets the needs of our employees and their working conditions," explains Schäfer. "Generative design has also changed how we think and how we approach the design of something. Generative design overcomes preconceived ideas and blind spots. No matter which of the design options we choose, we are sure that this production facility will work more efficiently and be more cost-effective to build."

The new production facility will be built next year on a vacant site within the Airbus campus in Hamburg. The criteria being evaluated by the development team using generative design include - with varying degrees of emphasis - efficient use of space, construction costs, sustainability, working conditions, logistics, customer experience, daylighting and flexibility.