Additive Magnesium Armrest

Our additive magnesium armrest passed the abuse tests carried out on the Ultraslim seat structure. The design of the armrest was based on the geometry of DOY Design’s Ultraslim seat and adapted for the manufacturing process and material properties. We used topology optimisation to reduce the overall weight of the part by over 30% whilst providing a functional outer skin for selective over moulding.

The armrest withstood the applied loads of 137kgf downwards and 90.7kgf sidewards during the tests with some overloading in both directions. The primary structure deformed as predicted however there was very little deformation in the armrest. The results of the project are very promising and provide some valuable information to support further development of the material and process.

This research and development project was enabled through the National Aerospace Technologies Exploitation Programme (NATEP) in the UK. DOY Design, Progressive Technologies and WMG at Warwick University collaborated on the project to explore the additive manufacture of magnesium alloys and their potential use in the aviation sector.

Armrest Abuse Test on DOY Ultraslim Seat

Gary DoyJanuary 25, 2023