Weight-optimized VIP conversion of an Airbus A320neo

Holistic mass management for exclusive cabin interiors

When converting an Airbus A320neo into a VIP commercial aircraft, the project team is confronted with considerable weight-related challenges. In particular, the increased cabin mass due to luxurious equipment elements leads to critical loads on the permissible mass limits such as MZFW and MTOW. Systematic mass savings based on structural, material and system lightweight design maintain the payload capacity and the target weight. This case study shows the engineering approach to mass impact analysis, MWE control and COG optimization.

Initial situation

An international operator of business charter flights is having a brand-new Airbus A320neo converted into an exclusive VIP configuration. The starting point is a series A320neo with an OEW (Operating Empty Weight) of approx. 44,000 kg.

The challenge

The VIP equipment includes lounge modules, office areas, a cabin sleeping module and a special cabin bathroom. This increases the cabin weight by around 2,500 kg compared to the standard equipment. The permissible zero fuel weight (MZFW = 64,300 kg) is exceeded by the additional built-in equipment with a full payload profile. In addition, the center of gravity (COG) must be kept within the permissible range of 23-36 % MAC without using trim weights.

Solution approach

A multi-stage mass property management system is implemented to ensure compliance with the mass limits. Through bottom-up mass recording, the use of mass growth allowances (MGA) and the use of mass properties reporting tools, such as our Smart Act ToolThis ensures transparent weight control.

The following weight optimization measures are used:

Lightweight material:

Substitution of heavy cabin materials with specially optimized aluminium and CFRP honeycomb sandwich panels with extremely high peel strength and the use of special lightweight inserts

  • Fiber composites (CFRP, GFRP, sandwich with honeycomb core):
    • Use for side panels, hatracks, office partitions
    • Advantages: high specific strength, low MOI, fire protection according to CS-25
  • High-strength extruded aluminum profiles:
    • Use for frame and support systems for furniture modules
    • Advantage: good machinability + crash behavior
    • CAD Design & Concepts
  • Connection technologies
  • Structural bonding + blind rivet combinations
  • Weight-optimized press-fit systems (instead of screw connections)
  • Integration of functional structures (e.g. cable ducts in support profiles)

(reduction: 600 kg).

Topology - Optimization

Lightweight structure:

  • Definition of an installation space and the load cases
  • Algorithmic reduction of non-load-bearing volumes
  • Achievable mass reduction: up to 60 %

Multiscale FEM & structural modeling

  • Use of macro, meso and micro models to identify critical stresses
  • Orthotropic and anisotropic material laws for sandwich panels or textile laminate structures
  • Strength and stability analyses incl. imperfection assessment (see also: Advanced_FEM_Portfolio)

Combined optimization approach

  • Combination of CFU-based load path analysis + CAD-integrated topology refinement
  • Focus on design-critical components: Cabinet frames and brackets, cabinet carcasses, Hatrack brackets, brackets

(reduction: 250 kg).

Lightweight construction system:

Simplification of the interfaces between structural components and electrical systems and optimization of the air conditioning supply lines through holistic analysis of the potential for functional integration

  • Functional integration: structural components simultaneously take on cladding or storage space functions
  • Reduction in part depth: simplification of modular units for more efficient assembly and disassembly
  • Weight-minimized design guidelines: design features adapted to automated production processes (RTM, prepreg)

(reduction: 450 kg).

In addition, the center of gravity is kept within the CG envelope thanks to optimized payload distribution.

Result

The payload loss can be limited to 300 kg thanks to these measures. The final OEW is 45,800 kg, which allows a ZFW of 62,800 kg - within the MZFW of 64,300 kg. The calculated COG is stabilized at 28 % MAC - optimal for all flight phases.

Are you planning a VIP, special mission or cargo conversion? Our experts for weight & balance and lightweight solutions will support you from the concept study to certification. Contact us for an individual feasibility analysis and weight forecast!

Literature and data sources

  • FAA: Weight and Balance Handbook (FAA-H-8083-1B)
  • EASA: Certification Specifications for Large Aeroplanes (CS-25)
  • SAWE: Recommended Practice No. RP7 - Mass Properties Terminology Standard
  • Airbus Aircraft Characteristics Manual A320neo, Rev. 2023
  • Own calculations based on OEM data sheets, MWE/OEW compilations
  • Glossary: Spacecraft & Aircraft Weight and Balance, internal source

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