Case Studies

Design and Analysis of Composite ECS Ducting Systems

The Client

The client is an aerospace tier-1 manufacturer of commercial Aircraft.

Business Need

The client sought design, analysis, and optimization of the ECS composites ducting systems. This included primary ducts and related components such as spuds, sleeves, insulations, and couplings. Environmental Control System (ECS) ducting helps in maintaining the cabin air quality in commercial aircrafts, enabling survival, safety, and comfort of passengers. The ECS ducts are installed within pressurized and unpressurized sections of fuselage and wing. They can be classified into moisture control, air distribution, lavatory and galley ventilation, bulk cargo heat, aft cargo heat, aft EE cooling, and personal air outlet based on the function.


Challenges in design and analysis of ECS composite ducting systems stem from:

  • Complex duct profiles - large number of interfaces
  • Varied loading conditions - gravity, pressure, impact, vibration, handling, and sonic fatigue
  • Design concepts - laminated, sandwich, circular, and rectangular
  • Complex constraints - engineering, assembly and manufacturing
  • Complex configuration of ducting and aircraft routing
Our Solution
  • Provided end-to-end solution (Concept design - detailed design, analysis and tooling) for composite ducts
  • Developed various analysis methodologies to qualify duct configurations (stiffness, strength, stability, vibration, and impact)
  • Developed diverse design methodologies to have uniformity in design, processes and deliverables, while reducing design and modeling time
  • Evaluated alternate design concepts and delivered optimum design with CAD models and cost-benefit analysis
  • Enabled extraction of material data for composite material using reverse engineering from test data

Our solution resulted in:

  • Optimized ducting system with fewer and standard types of connection
  • Correlated FE analysis with physical test below 5 percent accuracy that reduced further physical testing efforts
  • Developed multiple automation tools at different stages of analysis that reduced design and analysis cycle time by 25 percent
  • Developed various methodologies and best practices to design and analyze composite ducts
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