Sustainability-Driven Design Optimization of Aircraft Parts Using Mathematical Modeling

The design of aircraft components is a complex process that must simultaneously account for environmental impact, manufacturability, cost and structural performance to meet modern regulatory requirements and sustainability objectives. When these factors are integrated from the early design stages, the approach transcends traditional eco-design and becomes a genuinely sustainability-oriented design methodology. This study proposes a sustainability-driven design framework for aircraft components and demonstrates its application to a fuselage panel consisting of a curved skin, four frames, seven stringers, and twenty-four clips. The design variables investigated include the material selection, joining methods, and subcomponent thicknesses. The design space is constructed through a combinatorial generation process coupled with compatibility and feasibility constraints. Sustainability criteria are evaluated using a combination of parametric Life Cycle Assessment (LCA) and Life Cycle Costing (LCC) regression models, parametric Finite Element Analysis (FEA), and Random Forest surrogate modeling trained on a stratified set of simulation results. Two methodological pathways are introduced: 1. Cluster-based optimization, involving customized clustering followed by multi-criteria decision-making (MCDM) within each cluster. 2. Global optimization, performed across the full decision matrix using Pareto front analysis and MCDM techniques. A stability analysis of five objective-weighting methods and four normalization techniques is conducted to identify the most robust methodological configuration. The results—based on a full cradle-to-grave assessment that includes the use phase over a 30-year A319 aircraft operational lifetime—show that the thermoplastic CFRP panel joined by welding emerges as the most sustainable design alternative.