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Applied structural optimization of an aircraft wing spar for light sport aircraft
Cruz Ponce. Stephanie
Cruz Ponce. Stephanie
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2026-02-26
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Objective: This research investigates applied structural optimization of a wing spar for a Light Sport Aircraft (LSA), focusing to minimize cost and manufacturing complexity while meeting structural performance requirements related to strength, stiffness, and safety.
Background: Wing spars are primary load-bearing components that must withstand bending, shear, and fatigue loads while remaining lightweight and manufacturable. For LSAs, optimization must balance performance with cost and delivery constraints. The spar geometry analyzed in this study was provided by ILIOS Aerospace. The study emphasizes materials available through the Midwest supply chain, supporting Kansas' aerospace manufacturing ecosystem.
Methodology: The spar geometry was analyzed using MATLAB to compute bending moment, deflection, and shear stress under representative flight loading conditions. Two candidate materials, 7075-T6 aluminum and Ti-6Al-4V titanium, were evaluated using Lean Six Sigma (DMADV). Failure Mode and Effects Analysis (FMEA) identified material risks, while a Pugh Matrix quantitatively compared cost, manufacturability, delivery time, and structural performance.
Results: Both materials met structural requirements; however, 7075-T6 aluminum reduced spar mass by approximately 37% and material cost by nearly 90% compared to titanium. Aluminum also demonstrated superior machinability, shorter delivery lead times, and greater availability within the Midwest supply chain.
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Poster project completed at the Wichita State University, Department of Applied Engineering. Presented at the Kansas Undergraduate Student Research Day at the Capitol, Topeka, KS, February 26, 2026.
Sponsored by Undergraduate Research and Creative Activity Hub, Dorothy and Bill Cohen Honors College.
Sponsored by Undergraduate Research and Creative Activity Hub, Dorothy and Bill Cohen Honors College.
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Wichita State University