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Applied Sciences
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Optimized Design and Analysis of Mechanical Structure
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Optimized Design and Analysis of Mechanical Structure

A special issue of Applied Sciences (ISSN 2076-3417). This special issue belongs to the section "Materials Science and Engineering".

Deadline for manuscript submissions: 31 August 2026 | Viewed by 5237

Special Issue Editor

Dr. Hyun-Bum Park

E-Mail Website
Guest Editor
Department of Mechanical Engineering, Kunsan National University, 558 Daehak-ro, Miryong-dong, Gunsan 54150, Jeollabuk-do, Republic of Korea
Interests: composite material; structural design and analysis; optimal design; solid mechanics; FEM analysis; impact damage; failure criteria; manufacturing; structural test
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

I am pleased to announce a new open access Special Issue of the MDPI journal Applied Sciences dedicated to Structural Design and Analysis. The aim of this Special Issue is to collate the most recent research advancements in the field of mechanical and aerospace engineering considering composite applications. As Guest Editor of this Special Issue, I kindly invite you to submit full research articles and review manuscripts addressing, but not limited to, the following topics:

- Structural design using composites;

- Optimal design using composites;

- Structural analysis of design result;

- FEM analysis;

- Composite damage criteria;

- Application of fiber composites for aircraft;

- Application of sandwich composites for aircraft;

- Impact damage of structures;

- Composite specimen test of structural design for structures;

- Evaluation of mechanical properties using numerical method for composite structures;

- Evaluation of mechanical properties using specimen test for composite structures;

- Manufacturing process of composite structures for engineering;

- Manufacturing method of composite structures;

- Structural test.

Dr. Hyun-Bum Park
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 250 words) can be sent to the Editorial Office for assessment.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Applied Sciences is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2400 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • composite material
  • structural design and analysis
  • optimal design
  • solid mechanics
  • FEM analysis
  • impact damage
  • failure criteria
  • manufacturing
  • structural test

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Published Papers (5 papers)

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Research

23 pages, 8801 KB  
Article
Modelling, Parametric Study, and Optimisation of 3D Model-Scale Helicopter’s Rotor Blade with Piezoelectric Actuators
by Andrejs Kovalovs
Appl. Sci. 2026, 16(3), 1319; https://doi.org/10.3390/app16031319 - 28 Jan 2026
Cited by 1 | Viewed by 433
Abstract
The concept of active blade twisting as a method for reducing helicopter noise and vibration during flight is presented. Active twisting is achieved through piezoelectric actuators embedded in the blade skin, which generate dynamic twist when subjected to an electric field. Such dynamic [...] Read more.
The concept of active blade twisting as a method for reducing helicopter noise and vibration during flight is presented. Active twisting is achieved through piezoelectric actuators embedded in the blade skin, which generate dynamic twist when subjected to an electric field. Such dynamic deformation can lower fuel consumption while also reducing noise and vibration levels. A methodology for determining the optimal geometric dimensions of the cross-section of a helicopter blade, taking into account design constraints, is proposed to achieve the maximum twist angle of the blade under the action of piezoelectric actuators. First, a three-dimensional numerical model of the BO 105 model-scale rotor blade is developed in the finite element software ANSYS 16.0. The effect of the rotor blade’s cross-sectional dimensions on the cross-sectional properties and twist angle is investigated. It is found that skin thickness, spar flange thickness, and spar flange length affect the twist angle, with skin thickness showing a significant effect. Based on these results, an optimisation strategy is formulated to identify the optimal blade cross-section configuration to achieve the maximum twist angle. It was established that with the optimised geometric parameters of the cross-section the maximum active twist reaches 5.2°, while the positions of the elastic axis and the centre of gravity exhibit only minor deviations from those of the reference model. The placement of the piezoelectric actuators has a significant influence on both the flapwise bending stiffness and the torsional stiffness of the blade. Full article
(This article belongs to the Special Issue Optimized Design and Analysis of Mechanical Structure)
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15 pages, 3512 KB  
Article
Design of a Robot Vacuum Gripper Manufactured with Additive Manufacturing Using DfAM Method
by Bálint Leon Seregi, Adrián Bognár and Péter Ficzere
Appl. Sci. 2026, 16(2), 935; https://doi.org/10.3390/app16020935 - 16 Jan 2026
Cited by 1 | Viewed by 815
Abstract
This study presents a Design for Additive Manufacturing (DfAM)–driven redesign of an industrial robot vacuum gripper for Fused Deposition Modeling (FDM), focusing on the systematic transformation of a multi-part, machined aluminum assembly into a lightweight, support-minimized polymer component suitable for continuous industrial operation. [...] Read more.
This study presents a Design for Additive Manufacturing (DfAM)–driven redesign of an industrial robot vacuum gripper for Fused Deposition Modeling (FDM), focusing on the systematic transformation of a multi-part, machined aluminum assembly into a lightweight, support-minimized polymer component suitable for continuous industrial operation. Beyond a practical redesign, the work contributes a geometry-centered DfAM methodology that links internal channel topology, overhang control, and functional interfaces to manufacturability, vacuum performance, and cost efficiency. The development follows three iterative design revisions, progressing from a geometry-adapted baseline toward a fully DfAM-optimized solution. A key innovation is the introduction of support-free internal vacuum channels with triangular cross-sections, enabling complete elimination of soluble support material within enclosed cavities. This redesign reduces the internal vacuum volume by 44%, leading to faster vacuum response while maintaining functional suction performance. The optimized overhang angles, filleted load paths, and DfAM-compliant suction cup seats significantly reduce post-processing requirements and improve structural robustness. Experimental validation under industrial operating conditions confirms that the final design achieves reliable vacuum performance and mechanical durability. Compared to the original configuration, the optimized gripper demonstrates a substantial reduction in manufacturing complexity, with printing time reduced by approximately 50% and total part cost decreased by 26%, primarily due to eliminated tooling, reduced support material, and simplified post-processing. The presented results demonstrate that DfAM principles, when applied systematically at both global and internal geometry levels, can yield quantifiable functional and economic benefits. The findings provide transferable design guidelines for support-free internal channels and functional interfaces in FDM-manufactured vacuum components, offering practical reference points for researchers and practitioners developing end-use additive manufacturing solutions in industrial automation. Full article
(This article belongs to the Special Issue Optimized Design and Analysis of Mechanical Structure)
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15 pages, 3527 KB  
Article
Interfacial Evaluation of Wind Blade Carbon Spar-Cap Depending on Elimination Method of Intermediate Medium
by Jeong-Wan Park, Ha-Seung Park, Pyeong-Su Shin, Ki-Weon Kang and Sang-Il Lee
Appl. Sci. 2025, 15(24), 13281; https://doi.org/10.3390/app152413281 - 18 Dec 2025
Viewed by 561
Abstract
An Ultrasonic Test (UT), a type of non-destructive test, is used to inspect the manufacturing integrity of carbon spar-caps of wind blades. When performing a UT, an intermediate medium is used to improve the signal detection ability between the inspection target and the [...] Read more.
An Ultrasonic Test (UT), a type of non-destructive test, is used to inspect the manufacturing integrity of carbon spar-caps of wind blades. When performing a UT, an intermediate medium is used to improve the signal detection ability between the inspection target and the probe. However, if the intermediate-medium residue is not removed, it acts as a contaminant in the interface between the spar-cap and the blade skin. This has a negative effect on the adhesion characteristics. A quantitative method is required for removing the intermediate medium and peel ply after the UT. After the UT, the interfacial characteristics of the spar-cap surface are examined according to the method of removing the intermediate medium in this study. The static contact angle and the work of adhesion (Wa) were measured according to various surface treatment conditions. In addition, shear strength of the Carbon Fiber-Reinforced Plastic (CFRP) spar-cap was evaluated by the lap shear test. An optimized method of peel-ply removal combined with an intermediate medium was found in this study. An optimal guideline for intermediate-medium treatment could be proposed when evaluating the manufacturing integrity of real wind blade spar-caps using UT. Full article
(This article belongs to the Special Issue Optimized Design and Analysis of Mechanical Structure)
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14 pages, 2240 KB  
Article
Structural Design and Safety Analysis for Optimized Segmentation of Wind Turbine Blades with Composite Materials
by Wooseong Jeong and Hyunbum Park
Appl. Sci. 2025, 15(21), 11445; https://doi.org/10.3390/app152111445 - 26 Oct 2025
Cited by 2 | Viewed by 1143
Abstract
The study of segmentation of wind turbine blades has recently emerged as an area of interest. In this work, a segmented blade design was studied for transport. Wind turbine blades are becoming larger to generate higher power. Enlarging the wind turbine blade, however, [...] Read more.
The study of segmentation of wind turbine blades has recently emerged as an area of interest. In this work, a segmented blade design was studied for transport. Wind turbine blades are becoming larger to generate higher power. Enlarging the wind turbine blade, however, leads to increasing its weight and length. Enlarged wind turbine blades, however, become more difficult to transport. Therefore, this study designed the existing integral blade as the segmented type to make transport easy regardless of its length or weight. We propose a novel concept for wind turbine blade design. The joint part of the blade was designed with an adhesion method that improved the bolt fastened one. The adhesion method was used to minimize the increase in blade weight and also to make maintenance easier. The final blade segmentation position was determined and accordingly the structural design was performed. Finally, a longitudinal 50% point of blade was determined as the segmentation position. The safety factor for the blade’s joint part was 2.39. The safety of the design results was proven. Full article
(This article belongs to the Special Issue Optimized Design and Analysis of Mechanical Structure)
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17 pages, 4854 KB  
Article
A Multi-Scale Approach for Finite Element Method Structural Analysis of Injection-Molded Parts of Short Fiber-Reinforced Polymer Composite Materials
by Young Seok Cho, Byungwook Jeon, Juwon Min, Kiweon Kang and Haksung Lee
Appl. Sci. 2025, 15(13), 7434; https://doi.org/10.3390/app15137434 - 2 Jul 2025
Cited by 5 | Viewed by 1509
Abstract
Short fiber-reinforced polymer composites are extensively used in automotive structural components, such as engine mounts and motor mount brackets, due to their favorable strength-to-weight ratio. For motor mount brackets, accurate structural analysis requires consideration of fiber orientation, as it significantly affects the mechanical [...] Read more.
Short fiber-reinforced polymer composites are extensively used in automotive structural components, such as engine mounts and motor mount brackets, due to their favorable strength-to-weight ratio. For motor mount brackets, accurate structural analysis requires consideration of fiber orientation, as it significantly affects the mechanical behavior of the composite. This study aims to investigate the influence of fiber orientation heterogeneity on the mechanical properties of short fiber-reinforced polymer composites formed by injection molding. The spatial variation of the fiber orientation tensor, which evolves from the gate to the flow end during molding, presents challenges in experimental characterization. To address this, microscale analysis was conducted using injection-molded tensile specimens, followed by mesoscale modeling through representative volume elements (RVEs). Homogenization techniques were applied to predict effective mechanical properties, which were subsequently used to evaluate the performance of actual components at the macroscale. The findings demonstrate the importance of multi-scale modeling in capturing the anisotropic behavior of fiber-reinforced composites and provide a framework for more reliable structural analysis in automotive applications. Full article
(This article belongs to the Special Issue Optimized Design and Analysis of Mechanical Structure)
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