Client:
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VASHON Aircraft
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Project:
General Aviation 4-Passenger Aircraft – CNC-Machined Aluminum WTB Joint
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​Objective:
Replace a conventional rib-stiffened Wing-to-Body (WTB) Joint design with a lighter, CNC-machinable alternative using the same aluminum alloy and manufacturing method. The goal: reduce weight and cost without compromising structural performance or manufacturability.​​
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Baseline Challenge:
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The original part relied on traditional reinforcement ribs and deep-pocket machining to meet structural strength and stiffness. While effective, this approach led to excessive material use, and increased machining time. FEA revealed highly localized stress peaks at attachment regions, with much of the part carrying lower loads.
DuroWorks Approach:
We deployed a hybrid Generative Design workflow integrating:
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Topology Optimization under CNC constraints
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Refinement from organic GD output to a prismatic, machinable shape
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Lightweighting under real-world boundary and loading conditions
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Post-processed CAD geometry tailored for CNC routing from thick aluminum plate
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​​Results:
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Tangible Performance and Cost Gains
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25% weight reduction compared to baseline
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15% cost reduction in estimated CNC machining time and material waste
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Improved load distribution and structural efficiency
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Full compliance with baseline material and manufacturing methods
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Repeatable process for similar primary structure components
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Key Innovation:
Unlike typical GD workflows that result in abstract shapes usable only through expensive Additive Manufacturing, the DuroWorks process delivers quasi-final, CNC-ready components. This bridges the gap between conceptual optimization and real-world implementation, without changing the chosen materials and manufacturing process.
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Conclusion:
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This pilot project demonstrates a new value layer in advanced structural engineering. By integrating GD within conventional manufacturing constraints, DuroWorks enables organizations to extract maximum performance from their materials and reduce production cost, without requiring an overhaul of their supply chain or design process.