Case Study: Aircraft Carrier Alliance achieves 16% weight reduction and lower fabrication costs with Altair simulation-driven design

Creating a Structurally Efficient Design for the Queen Elizabeth Aircraft Carrier

Aircraft Carrier Alliance faced the challenge of making key structural decisions for the Queen Elizabeth aircraft carrier with limited data during concept and preliminary design phases, risking inefficient or over-engineered solutions. To evaluate simulation-driven design, Aircraft Carrier Alliance partnered with Altair (Altair ProductDesign), leveraging tools such as HyperMesh and OptiStruct to address complex mass–stiffness interactions in the FLYCO module.

Altair applied topology, size and shape optimization to define optimal stiffener placement, load paths and plate/opening dimensions for the FLYCO module. The Altair-led redesign met natural frequency, deflection, stress and buckling targets while reducing mass by 16%, using fewer parts and lowering fabrication costs, demonstrating clear cost, weight and performance benefits from simulation-driven design.

Aircraft Carrier Alliance