Systematic TRIZ and CFD Based Framework for Lightweight Additive Manufacturing of Flap Brackets

IMDC 2026, 1 International Machine Design Conference, İstanbul, Türkiye, 20 - 21 Temmuz 2026, ss.131-137, (Tam Metin Bildiri)

This study introduces a systematic engineering framework for the development of highlift

aerospace mechanisms, integrating TRIZ (Theory of Inventive Problem Solving) with

Computational Fluid Dynamics (CFD) and Design for Additive Manufacturing (DfAM).

Unlike conventional iterative design, this approach begins with a functional

decomposition to map energy and material flows, identifying the Fowler flap bracket as a

critical load-transmission node. To resolve the inherent technical contradiction between

structural integrity and weight, TRIZ principles specifically segmentation and porosity

were applied to transition from monolithic to organic geometries. The research leverages

CFD simulations to derive precise aerodynamic pressure distributions, ensuring that the

initial design space reflects realistic operational envelopes beyond simplified analytical

models. This physics-based data informs a SIMP-based topology optimization, which is

strictly constrained by Laser Powder Bed Fusion (L-PBF) manufacturing limits, such as

overhang angles and thermal gradients. The resulting design achieves a significant mass

reduction while maintaining airworthiness standards. By bridging conceptual design

finessed through TRIZ with high-fidelity CFD analysis and additive manufacturing

constraints, this framework offers a repeatable and traceable methodology for producing

the next generation of lightweight, high-performance aerospace components.