Facing stringent global carbon neutrality targets, the aviation industry urgently requires technological advancements, and consequently, lightweight design has become a key strategy for improving aero-engine fuel efficiency and reducing emissions. This paper examines the application of lightweight, high-strength structures in aero-engines, addressing the extreme operational environments and multifaceted design constraints. It focuses on achieving mass reduction while preserving structural integrity and lifespan, highlighting the important contributions of advanced approaches such as topology optimization and damage-tolerant design. Moreover, the paper examines the enabling role of advanced manufacturing technologies, especially additive manufacturing (AM), in realizing these designs. Emerging trends, including intelligent materials and AI-assisted design, are also discussed, offering insights into the future of sustainable aviation propulsion. The study finds that lightweight design can not only effectively reduce the structural mass of aero-engines but also enhance fuel efficiency and lower emissions without compromising performance, underscoring the significance of integrating new materials, precise design, and innovative manufacturing technologies for next-generation aero-engines.
Research Article
Open Access