Multi-Objective Material Selection Framework for Additively Manufactured Aircraft Wing Ribs

Aircraft wing ribs form the skeletal backbone of the wing. They maintain the aerodynamic profile and transfer structural loads from the skin to the spars. Conventional manufacturing processes struggle to produce complex geometries, making these components difficult and expensive to manufacture. Recent advances in additive manufacturing (AM) address these limitations. Additive manufacturing enables the production of complex geometries that significantly reduce weight. Most designers use the standard Ashby method to identify the strongest or lightest metal. However, they often overlook whether the material will behave as expected during additive printing. This research focuses on Multi-Objective Material Selection for the design of additive manufacturability of aircraft wing ribs using aluminium-based alloys. A key innovation in this research is the formulation of Hybrid Performance Indices (HPIs). These indices go beyond the traditional Ashby methodology. They mathematically couple structural efficiency metrics with a weighted Processability Factor. The structural metrics include specific density, stiffness, specific strength and Embodied Energy Strength to Embodied Energy Index. The Processability Factor accounts for local material availability, thermal conductivity, printability, recyclability and material cost. This dual evaluation assesses both structural integrity and manufacturing risk simultaneously. The process produces an Additive Pareto Optimal set of candidate materials. This helps engineers predict and prevent issues like warping and residual stress before printing begins. The framework also emphasises sustainability. It prioritises materials that minimise waste and considers Embodied Energy in the selection process. The framework identifies high-performance aluminium alloys that are specifically optimized for the additive manufacturing of aircraft wing ribs. It provides a definitive ranking based on their ability to withstand aerodynamic loads while remaining easy to print. This data-driven approach replaces trial and error with a clear selection matrix for the early design stage. It ensures that the chosen alloy is both structurally sound and manufacturable for aerospace applications.