For civil high-speed rotorcraft designed to operate at specific cruising altitudes, this study proposes nine structural design schemes for pressurized cabins. These schemes integrate commonly used materials and processing technologies in the aviation industry with advanced PRSEUS (Pultruded Rod Stitched Efficient Unitized Structure) technology. An analysis of the structural composition reveals that frames constitute 8–19% of the total structural weight, while stringers and beams make up 15–50%, and skins account for 11–25%, with thicknesses ranging from 1.0 mm to 2.0 mm. The separating interface of the pressurized cabin contributes 4–29% of the total structural weight. The weight distribution of each component in the pressurized cabin structure varies significantly depending on the chosen materials and processing technologies. Utilizing the Analytic Hierarchy Process (AHP), along with Gray Relational Analysis (GRA) and Dempster–Shafer (D-S) evidence theory, this study compares the simulation results of the nine schemes across multiple dimensions. The findings indicate that the configuration combining 7075 aluminum alloy and T300 composite material has the greatest advantages in terms of the high structural reliability of the configuration, light weight, mature processing technology, and low production cost. This comprehensive evaluation method quantitatively analyzes the factors influencing the structural configuration design of the pressurized cabin for civil high-speed rotorcraft, offering a valuable reference for the design of similar structures in related fields.

This paper presents the design and analysis of PRSEUS structures with no openings, small openings, and mid-sized openings. For the typical panel structure of the small-opening PRSEUS (Pultruded Rod Stitched Efficient Unitized Structure), five reinforcement schemes are developed using different types, such as mouth frames and convex platforms. Simulation analyses of tensile and compressive load are conducted. Compared to the non-opening PRSEUS panel, the small-opening PRSEUS panel’s maximum von Mises stress increases by 4.57 times under uniaxial tensile load, and the maximum von Mises stress increases by 2.55 times under uniaxial compressive load. The reinforcement efficiency of the small-opening PRSEUS panel in all five schemes exceeded 30%, Scheme E exhibits the highest load-bearing efficiency under both tensile and compressive load conditions, at 673.63 MPa/kg and 503.38 MPa/kg, respectively. For the typical PRSEUS panel structure with a mid-sized opening, three reinforcement schemes are proposed based on different methods, such as grid and cross-shaped reinforcement. These address the impact of mid-sized openings on the bearing capacity of the PRSEUS pane by analyzing the bearing efficiency of the three schemes. Compared to the non-opening PRSEUS panel, the maximum von Mises stress increases by 15.22 times under a uniaxial tensile load and by 32.45 times under a uniaxial compressive load. The reinforcement efficiency of the mid-sized-opening PRSEUS panel in these three schemes is greater than 50%, with Scheme III providing the highest bearing efficiency under a tensile load at 20.74 MPa/kg and 50.66 MPa/kg under a compressive load.