Study on Lightweight Design Strategies and Advanced Manufacturing Technologies for Aero-Engines
Research Article
Open Access
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Study on Lightweight Design Strategies and Advanced Manufacturing Technologies for Aero-Engines

Mingrui Cai 1*
1 Guanghua Qidi Education
*Corresponding author: 2277689590@qq.com
Published on 28 October 2025
Journal Cover
ACE Vol.200
ISSN (Print): 2755-273X
ISSN (Online): 2755-2721
ISBN (Print): 978-1-80590-491-5
ISBN (Online): 978-1-80590-492-2
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Abstract

Facing stringent global carbon neutrality targets, the aviation industry urgently requires technological advancements, and consequently, lightweight design has become a key strategy for improving aero-engine fuel efficiency and reducing emissions. This paper examines the application of lightweight, high-strength structures in aero-engines, addressing the extreme operational environments and multifaceted design constraints. It focuses on achieving mass reduction while preserving structural integrity and lifespan, highlighting the important contributions of advanced approaches such as topology optimization and damage-tolerant design. Moreover, the paper examines the enabling role of advanced manufacturing technologies, especially additive manufacturing (AM), in realizing these designs. Emerging trends, including intelligent materials and AI-assisted design, are also discussed, offering insights into the future of sustainable aviation propulsion. The study finds that lightweight design can not only effectively reduce the structural mass of aero-engines but also enhance fuel efficiency and lower emissions without compromising performance, underscoring the significance of integrating new materials, precise design, and innovative manufacturing technologies for next-generation aero-engines.

Keywords:

Aero-engine, Lightweight Design, Additive Manufacturing, Structural Integrity

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Cai,M. (2025). Study on Lightweight Design Strategies and Advanced Manufacturing Technologies for Aero-Engines. Applied and Computational Engineering,200,1-6.

References

[1]. IATA. (2023). Net-Zero Carbon Emissions by 2050: A Roadmap for the Global Air Transport Industry. IATA. https: //www.iata.org/contentassets/4b18fa1ac4a246879c058cf75954dbda/netzero-roadmaps-presentation-agm2023.pdf

[2]. Chen, S, & Wang, M.Y. (2007) Designing Distributed Compliant Mechanisms With Characteristic Stiffness. Proceedings of the International Design Engineering Technical Conferences and Computers and Information in Engineering Conference, 33-45.

[3]. Zhang, W., Yuan, J., Zhang, J. et al. (2016). A new topology optimization approach based on Moving Morphable Components (MMC) and the ersatz material model. Struct Multidisc Optim 53, 1243-1260.

[4]. Xiong, Y.L., Yao, S., Zhao, Z.L., & Xie, Y.M. (2020). A new approach to eliminating enclosed voids in topology optimization for additive manufacturing. Additive Manufacturing, 32, 101006.

[5]. Boyce, M.P. (2011). Gas Turbine Engineering Handbook. Butterworth-Heinemann.

[6]. Reed, R.C. (2006). The Superalloys: Fundamentals and Applications. Cambridge University Press.

[7]. Wang, R., Jiang, K., Jing, F., & Hu, D. (2016). Thermomechanical fatigue failure investigation on a single crystal nickel superalloy turbine blade. Engineering Failure Analysis, 66, 132-145.

[8]. Ding, C. , Qi, X. , Gao, Z. and Chang, L. (2020) The Influence of Centrifugal Force on the Interference Fit of High-Speed Electric Spindle. World Journal of Engineering and Technology, 8, 792-799.

[9]. Yuan, H., Yang, W., Zhao, T., & Liang, M. (2015). Effects of stator-rotor interaction on unsteady aerodynamic load of compressor rotor blades. Journal of Vibroengineering, 17(5), 2591-2608.

[10]. Kırca, A. İ., Diltemiz, S. F., Yumrukaya, S., Batar, A. (2023). Evaluation Of Foreign Object Damage On The Fan Blades with Microscopic Techniques. Duzce University Journal of Science and Technology, 11(5), 2341-2351.

[11]. Stringer, J., & Wright, I. G. (1995). Oxidation and Hot Corrosion of Superalloys. Materials Science and Technology, 11(11), 1071-1078.

[12]. Powell, B.E., Hawkyard, M., & Grabowski, L. (1997). The growth of cracks in Ti-6Al-4V plate under combined high and low cycle fatigue. International Journal of Fatigue, 19(93), 167-176.

[13]. Cumpsty, N. A., & Heyes, A. G. (2003). Jet Propulsion: A Simple Guide to the Aerodynamic and Thermodynamic Design and Performance of Jet Engines (3rd ed.). Cambridge University Press.

[14]. Ashby, M.F. (2016). Materials Selection in Mechanical Design (5th ed.). Butterworth-Heinemann.

[15]. Carter, T.J. (2019). Common Failures in Gas Turbine Blades. Engineering Failure Analysis, 105, 374-385.

[16]. Guo, Z., Song, Z., Qin, X., et al. (2024). A rapid multidisciplinary life optimization method for turbine blades with a large number of film cooling holes. Applied Thermal Engineering, 245, 122824.

[17]. Effen, C., Riegel, B., Gerhard, N., et al. (2025). Manufacturing Considerations in the Aerodynamic Design Process of Turbomachinery Components. Processes, 13(8), 2363.

[18]. R, S., P, G., Gupta, R.K. et al. (2019). Laser Shock Peening and its Applications: A Review. Lasers Manuf. Mater. Process. 6, 424-463.

References

[1]. IATA. (2023). Net-Zero Carbon Emissions by 2050: A Roadmap for the Global Air Transport Industry. IATA. https: //www.iata.org/contentassets/4b18fa1ac4a246879c058cf75954dbda/netzero-roadmaps-presentation-agm2023.pdf

[2]. Chen, S, & Wang, M.Y. (2007) Designing Distributed Compliant Mechanisms With Characteristic Stiffness. Proceedings of the International Design Engineering Technical Conferences and Computers and Information in Engineering Conference, 33-45.

[3]. Zhang, W., Yuan, J., Zhang, J. et al. (2016). A new topology optimization approach based on Moving Morphable Components (MMC) and the ersatz material model. Struct Multidisc Optim 53, 1243-1260.

[4]. Xiong, Y.L., Yao, S., Zhao, Z.L., & Xie, Y.M. (2020). A new approach to eliminating enclosed voids in topology optimization for additive manufacturing. Additive Manufacturing, 32, 101006.

[5]. Boyce, M.P. (2011). Gas Turbine Engineering Handbook. Butterworth-Heinemann.

[6]. Reed, R.C. (2006). The Superalloys: Fundamentals and Applications. Cambridge University Press.

[7]. Wang, R., Jiang, K., Jing, F., & Hu, D. (2016). Thermomechanical fatigue failure investigation on a single crystal nickel superalloy turbine blade. Engineering Failure Analysis, 66, 132-145.

[8]. Ding, C. , Qi, X. , Gao, Z. and Chang, L. (2020) The Influence of Centrifugal Force on the Interference Fit of High-Speed Electric Spindle. World Journal of Engineering and Technology, 8, 792-799.

[9]. Yuan, H., Yang, W., Zhao, T., & Liang, M. (2015). Effects of stator-rotor interaction on unsteady aerodynamic load of compressor rotor blades. Journal of Vibroengineering, 17(5), 2591-2608.

[10]. Kırca, A. İ., Diltemiz, S. F., Yumrukaya, S., Batar, A. (2023). Evaluation Of Foreign Object Damage On The Fan Blades with Microscopic Techniques. Duzce University Journal of Science and Technology, 11(5), 2341-2351.

[11]. Stringer, J., & Wright, I. G. (1995). Oxidation and Hot Corrosion of Superalloys. Materials Science and Technology, 11(11), 1071-1078.

[12]. Powell, B.E., Hawkyard, M., & Grabowski, L. (1997). The growth of cracks in Ti-6Al-4V plate under combined high and low cycle fatigue. International Journal of Fatigue, 19(93), 167-176.

[13]. Cumpsty, N. A., & Heyes, A. G. (2003). Jet Propulsion: A Simple Guide to the Aerodynamic and Thermodynamic Design and Performance of Jet Engines (3rd ed.). Cambridge University Press.

[14]. Ashby, M.F. (2016). Materials Selection in Mechanical Design (5th ed.). Butterworth-Heinemann.

[15]. Carter, T.J. (2019). Common Failures in Gas Turbine Blades. Engineering Failure Analysis, 105, 374-385.

[16]. Guo, Z., Song, Z., Qin, X., et al. (2024). A rapid multidisciplinary life optimization method for turbine blades with a large number of film cooling holes. Applied Thermal Engineering, 245, 122824.

[17]. Effen, C., Riegel, B., Gerhard, N., et al. (2025). Manufacturing Considerations in the Aerodynamic Design Process of Turbomachinery Components. Processes, 13(8), 2363.

[18]. R, S., P, G., Gupta, R.K. et al. (2019). Laser Shock Peening and its Applications: A Review. Lasers Manuf. Mater. Process. 6, 424-463.

Cite this article

Cai,M. (2025). Study on Lightweight Design Strategies and Advanced Manufacturing Technologies for Aero-Engines. Applied and Computational Engineering,200,1-6.

Data availability

The datasets used and/or analyzed during the current study will be available from the authors upon reasonable request.

About volume

Volume title: Proceedings of CONF-MCEE 2026 Symposium: Advances in Sustainable Aviation and Aerospace Vehicle Automation

ISBN: 978-1-80590-491-5(Print) / 978-1-80590-492-2(Online)
Editor: Ömer Burak İSTANBULLU
Conference website: https://2025.confmcee.org/kayseri.html
Conference date: 14 November 2025
Series: Applied and Computational Engineering
Volume number: Vol.200
ISSN: 2755-2721(Print) / 2755-273X(Online)

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