Aircraft pose unique design challenges in that they need to be lightweight in order to carry a useful load, but make them too light and they become frail. Choice of materials is critical and aluminum is popular among legacy manufacturers due to its high strength to weight ratio and its ability to conform. Engineering component junctions could provide rigidity without adding weight. Add a crease to a flat panel and it becomes stiffer. Well-placed round holes in a solid beam can reduce weight without compromising integrity.
Other materials have been used over the years, like wood and steel but they need to be thin to be viable and they still carry weight and bulk. Modern construction techniques using composites and fiberglass can offer sleek, seamless designs but require clean, enormous fabrication and curing facilities and the associated costs can be prohibitive in many cases.
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