Antler-Inspired Cellular Design for Enhanced Mechanical Performance of Additively Manufactured Aircraft Engine Mount Brackets

Bio-inspired structures can deliver outstanding mechanical properties, but their complex geometries make conventional fabrication challenging. Additive manufacturing enables the production of these intricate architectures and is increasingly used in aerospace where components experience high loads and strict safety constraints. This study enhances the mechanical performance of an aircraft engine mount bracket by designing and optimising a deer antler-inspired unit-cell architecture. Nine unit-cell configurations are evaluated using finite element analysis and electro-mechanical compression testing. The optimal design achieved a maximum yield force of 30.7 kN with a minimal deformation of 2.56 mm, representing a 44.84% improvement over the lowest-performing configuration, which failed at 16.9 kN. Finite element analysis predictions showed strong agreement with experimental results, with a nominal error of ±4%, consistent with typical experimental variability. These findings demonstrate the potential of antler-inspired cellular architectures to improve the strength and reliability of additively manufactured aerospace components.