Integrating Sustainability in Aircraft Component Design: Towards a Transition from Eco-Driven to Sustainability-Driven Design

Eco-design is an innovative design methodology that focuses on minimizing the environmental footprint of industries, including aviation, right from the conceptual and development stages. However, rising industrial demand calls for a more comprehensive strategy wherein, beyond environmental considerations, competitiveness becomes a critical factor, supported by additional pillars of sustainability such as economic viability, circularity, and social impact. By incorporating sustainability as a primary design driver at the initial design stages, this study suggests a shift from eco-driven to sustainability-driven design approaches for aircraft components. This expanded strategy considers performance and safety goals, environmental impact, costs, social factors, and circular economy considerations. To provide the most sustainable design that balances all objectives, these aspects are rigorously quantified and optimized during the design process. To efficiently prioritize different variables, methods such as multi-criteria decision-making (MCDM) are employed, and a sustainability index is developed in this framework to assess the overall sustainability of each design alternative. The most sustainable design configurations are then identified through an optimization process. A typical aircraft component, namely a hat-stiffened panel, is selected to demonstrate the proposed approach. The study highlights how effectively sustainability considerations can be integrated from the early stages of the design process by exploring diverse material combinations and geometric configurations. The findings indicate that the type of fuel used, and the importance given to the sustainability pillars—which are ultimately determined by the particular requirements and goals of the user—have a significant impact on the sustainability outcome. When equal prioritization is given across the diverse dimensions of sustainability, the most sustainable option appears to be the full thermoplastic component when kerosene is used. Conversely, when hydrogen is considered, the full aluminum component emerges as the most sustainable choice. This trend also holds when environmental impact is prioritized over the other aspects of sustainability. However, when costs are prioritized, the full thermoplastic component is the most sustainable option, whether hydrogen or kerosene is used as the fuel in the use phase. This innovative approach enhances the overall sustainability of aircraft components, emphasizing the importance and benefits of incorporating a broader range of sustainability factors at the conceptual and initial design phases.