Integration of active flow control technology into civil transport aircraft is a highly desired objective due to the potential reductions in part count, weight, and recurring manufacturing costs. This study develops an optimal design for integrating a fluidic oscillator into the leading-edge of a trailing-edge flap structure on a civil transport aircraft. The design incorporates design specifications set by members of the aerospace industry, robust design methodologies, and simulation studies to create three separate designs that can be mass-produced. An analysis of the manufacturing, assembly, material, and weight reveals the cost of the design with respect to its production rate, which ranges from about $4090 per aircraft for low-production volumes to about $2600 per aircraft for high-production volumes. As a result, this study provides a basis for the design of manufacturing and assembly techniques to integrate active flow control technology into civil transport aircraft.
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