Optimizing Wing Structural Design: Evaluating Infill Geometry and Print Orientation on the Structural Integrity of PLA Components
Abstract
In the AIAA Design, Build, Fly (DBF) Competition, material selection is a critical engineering consideration due to the need for balancing structural performance with logistical constraints. This study examines the 3D-printed polylactic acid (PLA) wing ribs to determine the optimal infill pattern and percentage based on weight, time, and cost. PLA is selected due to supply limitations and unavailability of CNC machining and ensures timely aircraft production by allowing parts to be manufactured on demand. Testing for the 3D-printed rib sections includes the grid, honeycomb, and gyroid patterns with 10%, 15%, and 20% densities. The quarter chord is subjected to a load force to examine how the worst-case scenario load, applied to the aerodynamic center, affects the structure of the rib. These findings are used to guide the selection of future PLA rib designs to support the construction of a functional flying aircraft.
Publication Title
Regional Student Conferences 2026
Recommended Citation
Tan, X., Lee, M., Mendoza, B., Seelam, B., Marchetta, J., & Foti, D. (2026). Optimizing Wing Structural Design: Evaluating Infill Geometry and Print Orientation on the Structural Integrity of PLA Components. Regional Student Conferences 2026 https://doi.org/10.2514/6.2026-112557
