TOPOLOGY OPTIMIZED DESIGN AND FABRICATION OF AN AIR CRAFT SEAT BELT BUCKLE USING PA11 AND PA12

Mechanical Engineering

The aerospace sector requires components that combine minimum weight with high structural strength to enhance fuel efficiency, operational performance, and passenger safety. This study presents the topology optimization, design, and fabrication of an aircraft seat belt buckle using advanced polymer materials, Polyamide 11 (PA11) and Polyamide 12 (PA12). The main objective was to achieve substantial weight reduction while preserving or improving the mechanical integrity of the buckle through efficient material redistribution. A three-dimensional CAD model of the buckle was developed and subjected to topology optimization to eliminate non-critical material from low-stress regions without affecting functional performance. The optimized geometry was fabricated using additive manufacturing, enabling high dimensional accuracy, reduced material wastage, and efficient production of complex lightweight structures. Mechanical characterization of the fabricated specimens was performed through tensile testing, hardness evaluation, and surface roughness measurement. The experimental results were correlated with simulation outcomes to validate the reliability of the optimized design. Comparative analysis showed that PA12 exhibited superior tensile strength (52 MPa), yield strength (38 MPa), hardness (78 Shore D), and improved surface finish, whereas PA11 demonstrated higher elongation (35%) and better flexibility. The optimized buckle achieved an overall weight reduction of approximately 60–70% compared with conventional metallic buckles while maintaining required structural performance. The findings confirm that topology optimization integrated with additive manufacturing is a highly effective strategy for developing lightweight, durable, and high-performance aerospace components. The study also establishes PA12 as the preferred material for load-bearing buckle applications, while PA11 remains suitable for components requiring greater toughness and flexibility.

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