Multidisciplinary Design Optimization of Composite Spacecraft Structures using Lamination Parameters and Integer Programming

The digital transformation of engineering design processes is essential for the aerospace industry to remain competitive in the global market. Multidisciplinary design optimization (MDO) frameworks play a crucial role in this transformation by integrating various engineering disciplines and enabling the optimization of complex spacecraft structures. Since the design team consists of multiple entities from different domains working together to build the final product, the design and analysis tools must be readily available and compatible. An integrated approach is required to handle the problem's complexity efficiently. Additionally, most aerospace structures are made from composite panels. It is challenging to optimize such panels as they require the satisfaction of constraints where the design ply thicknesses and orientations can only take discrete values prescribed by the manufacturers. Heuristics such as particle swarm or genetic algorithms are inefficient because they provide sub-optimal solutions when the number of design variables is large. They also are computationally expensive in handling the combinatorial nature of the problem. To overcome these challenges, this work proposes a two-fold solution that integrates multiple disciplines and efficiently optimizes composite spacecraft structures by building a rapid design framework. The proposed model-based design framework for spacecraft structures integrates commercially available software from Siemens packages such as NX and HEEDS and open-source Python libraries. The framework can handle multiple objectives, constraint non-linearities, and discrete design variables efficiently using a combination of black-box global optimization algorithms and Mixed Integer Programming (MIP)-based optimization techniques developed in this work. Lamination parameters and MIP are adopted to optimize composite panels efficiently. The framework integrates structural, thermal and acoustic analysis to optimize the spacecraft's overall performance while satisfying multiple design constraints. Its capabilities are demonstrated in optimizing a small spacecraft structure for required structural performance under various static and dynamic loading conditions when the spacecraft is inside the launch vehicle or operating in orbit.