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Purpose

The purpose of this paper is to present an overview of the aircraft design problems which can be efficiently solved using a special solid finite‐element model of variable density.

Design/methodology/approach

Optimization algorithms based on fully‐stressed design philosophy, sensitivity coefficients, and employing material density as a design variable provide means to generate optimal topology layouts, subject to a wide range of design constraints. A novel non‐dimensional criterion is used for assessment of load‐carrying efficiency of structures and knowledge accumulation.

Findings

Variable density model, together with non‐dimensional criterion of structural efficiency, yields a new versatile approach to a structural weight estimation at early design stages. New weight equations are used. The approach is a powerful tool for addressing complex multidisciplinary design optimization (MDO) problems such as aerodynamic load prediction taking aeroelastic deformations into account and aerodynamic‐structural design optimization of unconventional aircraft configurations.

Research limitations/implications

For accurate estimation of wing weight and deflections, the method should be tuned by regression analysis of existing aircraft to properly account for secondary structural weight.

Practical implications

The developed software tools for aeroelastic behaviour prediction and coupled aerodynamic‐structural design optimization are ready for integration into the complex MDO framework.

Originality/value

The variable density model is shown to have broad predictive opportunities for design problems at early stages of a product development.

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