Sustainable design of train seats using finite element analysis and multiobjective optimization

The transport sector is one of the largest contributors to environmental impacts due to its reliance on nonrenewable resources, high energy consumption, and significant greenhouse gas emissions. Rail transport, responsible for 11% of freight and 8% of passenger transport in Europe, presents opportunities for increased sustainability. This study addresses the multiobjective challenge of reducing the weight of suburban train seat structures while maintaining stiffness and adhering to production, ergonomic, and esthetic constraints. A new seat structure was designed, reducing its mass by over 50% without compromising mechanical performance, using design optimization techniques such as the Direct MultiSearch method and Siemens NX Nastran's optimization solver (SOL200). The design adhered to traditional manufacturing constraints, including welding, riveting, and bending. finite element analysis guided the optimization process, identifying parameters suitable for improvement. The weight reduction enables increased passenger capacity without altering the train's overall mass or energy consumption, improving energy efficiency per passenger. This study not only aligns with sustainability goals in rail transport but also serves as a replicable framework for optimizing passenger seat designs across various transport modes, enhancing the efficiency and competitiveness of sustainable mobility systems.