A Computational Framework for Early-Stage eVTOL Crashworthiness Evaluation

This work presents a numerical methodology aimed at supporting the early-stage crashworthiness evaluation of eVTOL aircraft. A simplified simulation framework combining finite element and multi-body modeling was developed to enable fast exploration of a broad design space with limited computational effort. A two-step design of experiments supported by surrogate modeling allowed for the identification of feasible design regions and the quantification of parameter influence through Sobol' sensitivity indices. The results reveal that tuning the different energy-absorbing components to ensure a synergistic system response plays a central role in minimizing lumbar load peaks while avoiding seat bottoming. Notably, a compliant subfloor benefits both occupant survivability and the loads experienced by the airframe and the battery pack. These findings underscore the importance of integrating crashworthiness criteria from the earliest stages of eVTOL structural design and demonstrate the potential of the proposed approach to provide requirements that can guide design decisions.