Abstract
<jats:p>This paper examines modern approaches to wing design for light civil aircraft (LCA) within the framework of integrated design methodology. The analysis traces the evolution of methods from classical statistical-analytical techniques and sequential finite element (FEM) approaches through contemporary multidisciplinary design optimization (MDO) and parametric 3D modeling in CAD/CAM/CAE/PLM environments. Examination of key methodologies reveals both capabilities and limitations: statistical-analytical methods offer rapid assessment but typically achieve only 10–20% accuracy due to the generalized character of empirical correlations; aerodynamic optimization via adjoint sensitivity methods can handle hundreds of shape variables yet depends heavily on initial geometry and computational expense. Topology optimization using SIMP methodology demonstrates wing mass reduction potential of 7–15%, although the resulting material distributions require further practical interpretation. Combined with polymer composite materials and optimized fiber layups [0°/±45°/90°], the combined use of topology optimization and composite materials can reduce wing mass by roughly one third for the considered configurations. Master geometry within CAD/CAE/PLM integration emerges as a critical coordination mechanism synchronizing disciplinary decisions, significantly reducing the number of design iterations required in current projects. The methodology developed at the National Aerospace University demonstrates conceptual alignment with Siemens NX's Master Model and Dassault 3DEXPERIENCE's Virtual Twin while remaining specifically tailored to LCA production constraints and computational resource limitations. The digital twin concept offers promising evolution pathways, coupling aerodynamic, structural, and durability models with structural health monitoring data to enable transition from scheduled to condition-based maintenance. A method classification framework by disciplinary integration level (sequential → optimization-based → fully integrated) has been formulated with quantitative criteria for method selection across design stages. Statistical analysis of leading manufacturers (GAMA 2023) indicates approximately 58% of new piston aircraft now employ polymer composites for wings (976 aircraft), with box-spar configurations in 51.4% of deliveries, while aluminum structures retain 42% market share. However, only one major manufacturer has adopted full multidisciplinary optimization; most use sequential verification despite composite construction. This gap between academic MDO capabilities and industrial practice underscores the relevance of developing an adapted integrated design methodology suitable for small design teams. </jats:p>