Browse Topic: Design processes
A 4-rotor uninhabited air vehicle is described, with a primary mission of supporting personnel fighting wildfires. The paper demonstrates the use of technical design tools for a small Uninhabited Aircraft System (sUAS). A description of the design process is provided, including developing requirements, identifying constraints, the software tools employed, and examination of results. The vehicle is capable of delivering more than 20 kg of supplies to a delivery point 10 nm away while penetrating 30 kt winds. The sized vehicle is transportable in a medium-duty pickup truck and can be picked up and moved for ground handling by one or two individuals. The vehicle information will be publicly released for NDARC software users. Future work will examine other requirements, such as maneuvering and gust rejection.
With performance advances proposed for the Future Vertical Lift suite of aircraft and advancements in the electronic battlefield, it is imperative that advanced materials and concepts be included in the vehicle designs to meet the aggressive weight reduction objectives, structural requirements, and operational environment capabilities. Integrating electromagnetic (EM) shielding during the design process offers an opportunity to make progress towards the performance goals. To this end, efforts must be made to minimize the impact of this shielding to platform weight and structural performance. This article presents work to develop a hybrid multifunctional composite material technology that incorporates copper mesh into a carbon fiber and thermoplastic matrix structural composite material to achieve required levels of EM shielding and high levels of structural efficiency while reducing the overall weight of the system. This article focuses on the design of a representative helicopter tailcone as means of illustrating expected improvements in weight and manufacturing cost. Baselines that include structure fabricated from aluminum and thermoset composite are established and predicted improvements quantified.
An extensive test campaign was conducted at the National Full-Scale Aerodynamics Complex 40- by- 80-Foot wind tunnel to acquire performance, loads, and acoustics measurements of the Joby Aviation propeller across a variety of operating conditions. The dataset provided validation of the design methodology as well as verification of computational tools. The Vold-Kalman filter was used to extract the shaft-coherent propeller noise in hover to obtain the residual noise, representing the broadband noise. This data verified broadband noise tip speed scaling laws as well as a low-order empirical model for overall sound pressure level. The OVERFLOW/PSU-WOPWOP method was used to simulate the propeller in pure edgewise flight and shown to accurately predict propeller performance. The low-frequency acoustics were predicted well but the solver underpredicted frequencies above 300 Hz, possibly due to the inability to capture the turbulent component of the blade-wake and blade-vortex interaction. The computational method was used to simulate the propeller at various angles of attack in low-speed edgewise flight and captured trends and spectral content up to 1 kHz. The predictions showed noise sources moving from root to tip as the propeller angle of attack increased. However, the high-frequency content was not captured for all cases. The experimental campaign was successful in characterizing the acoustics of the Joby Aviation propeller, but more research is needed to be able to properly predict and understand the noise sources throughout the flight envelope.
Accurate simulation of fluid-structure interactions (FSI) is critical for designing aircraft systems, particularly for applications involving fuel tank sloshing and large deformations. Traditional added mass methods often fail to capture the nonlinear and frequency-dependent behavior of these coupled systems. This study applies the Finite Pointset Method (FPM), a mesh-free computational fluid dynamics (CFD) technique, coupled with an explicit finite element solver, to predict complex FSI phenomena. Validation is performed using benchmark experiments, including a harmonic tank sloshing test and a guided plate ditching scenario, with results demonstrating strong agreement with measured pressures and structural responses. Additional validation on a composite fuel tank drop impact test confirms FPM's ability to model large deformations and rupture under dynamic loading. The findings highlight FPM's robustness and adaptability for aerospace FSI problems, offering a powerful alternative for virtual prototyping and certification workflows where conventional methods are insufficient.
A cooperative acoustics flight test campaign between the US Army and NASA was performed in which design of experiments (DOE) approaches were used to plan the flight test conditions. Three DOE designs were used, a face centered central composite design, circumscribed central composite design, and a hexagonal design. A traditional one-factor-at-a-time approach was also used, and interpolation points were planned to test for the strength of the DOE approaches. This paper documents the design methodology, discusses how response surface models were fit to the data, evaluates the overall response of the models, and evaluates the individual DOE designs. The response surface models were also used to design new test conditions of interest during the experiment, and that process is also documented. For the first time, DOE was shown to be an exceptionally useful tool for rotorcraft acoustics flight test planning, while the full power of the approach has yet to be reached.
U.S. Army Combat Capabilities Development Command (DEVCOM), Aviation & Missile Center (AvMC) developed a Digital Backbone for the Rotorcraft Applied Systems Concepts Airborne Lab (RASCAL-X) UH-60M for rapid Modular Open Systems Approach (MOSA) mission system integrations. The RASCAL-X Digital Backbone is the cornerstone of a unique experimental flight test capability connecting the experimental research flight control system with the Mission Systems Flying Testbed (MSFTB) and other mission system components. The Digital Backbone with MSFTB provides a suite of capabilities to integrate, assess, and flight test Mission Systems Under Test. The RASCAL-X Digital Backbone supports many of the physical aspects of mission system integration by providing Nodal Points with provisioning for power, data, and connectivity. Numerous challenges in Digital Backbone design, fabrication and installation were successfully addressed and solved during the development effort. The RASCAL-X Digital Backbone installation was completed in February 2025.
The advent of electric propulsion technology has led to a paradigm shift in aircraft design over the past few decades. This shift has expanded the possibilities for design and optimization processes more than at any previous time. To support these advancements, efficient flight dynamics simulation models that can be employed in iterative optimization and design processes are essential. Among the modules of a typical flight dynamics framework—namely, control, flight dynamics, and aerodynamics—the aerodynamics module, which includes the rotor performance model, generally demands the most computational effort, thereby limiting simulation efficiency. In this study, a novel machine learning (ML)-assisted flight dynamics framework is developed, incorporating a Neural Network Blade Element Theory (NN-BET) model as the rotor performance module. The results show a 7- to 8-fold reduction in computational time compared to fast, physics-based frameworks utilizing efficient Blade Element Momentum Theory (BEMT) models, without compromising predictive accuracy. Furthermore, the modular architecture of the framework allows for easy adaptation to a wide range of practical applications by replacing modules with functionally equivalent alternatives. The demonstrated accuracy and computational efficiency of the proposed flight dynamics framework make it a highly promising candidate for optimization and design applications.
This study presents computational analyses of coaxial rotor hub flows and validation against experimental data obtained from the fifth Rotor Hub Flow Prediction Workshop. Experiments were conducted in a 12-inch diameter water tunnel at Pennsylvania State Applied Research Laboratory, employing tomographic particle-image velocimetry (Tomo-PIV) and precise hub drag measurements. Three CFD codes (UMD Mercury, CREATETM-AV Helios, and OVERFLOW) utilizing hybrid Reynolds-Averaged Navier-Stokes (RANS) / Large Eddy Simulation (LES) modeling based on Spalart–Allmaras turbulence model, were applied to replicate and analyze hub flows. Counter-rotating coaxial rotor hubs under free-air condition was simulated as the simplest case and the hub drags are compared between the three CFD codes. The full water tunnel configuration, consisting of two hubs, a fairing, and shafts, was also simulated and compared to experimental results, with a focus on hub drag, wake velocity fields, and turbulence quantities. Results demonstrated that the computational frameworks effectively captured key flow physics, although some discrepancies in drag harmonics, wake velocity and turbulence intensity magnitudes were observed. Additionally, the study highlighted the impact of rotor hub geometry and installation of sail-fairing on drag and wake structures. These findings contribute to improve computational predictions, essential for designing high-speed rotor hub configurations.
This paper will present the use of a licensed open-source software application based on commercially available off-the-shelf hardware for the control and data acquisition of aerospace system integration test rigs. System integration test rigs are complex systems requiring real-time deterministic control and high-speed data acquisition. Various aircraft flight systems and subsystems can be tested to see if they interact as they would on the aircraft without an airframe. These systems are critical to ensure interoperability during the development phase and facilitate the interchangeability of actual flight hardware, prototypes, and simulation models throughout the development cycle. Deploying open, flexible, and highly configurable real-time control and data acquisition systems ensures that development milestones will be achieved cost-effectively, whether using actual flight hardware or working with a simulation. This is because, as the prototype hardware is developed, the remaining aircraft systems can still be tested by interacting with the model.
This work proposes an experimental and numerical activity aimed at developing methods to evaluate the strength and toughness of Kevlar/Epoxy composite fastened joints used in aeronautical structures and exposed to high energy impacts. Experiments were conducted using an Arcan rig that allowed applying various loading conditions, ranging from pull-through to bearing. A non-linear model of the material based on a bi-phasic decomposition and hybrid meshing technique was built and calibrated. The material model was used to develop a high-fidelity model of the junction to simulate the pull-through test with the Abaqus/Explicit finite element solver. The results of the analysis point out that the implemented progressive damage laws are capable of achieving an appreciable experimental-numerical correlation, both from the qualitative and the quantitative standpoint. Therefore, the combined experimental-numerical approach is promising for developing a validated numerical tool capable of predicting the overall response of different junctions with minimal experimental effort, so to provide data for simulating impact scenarios at the rotorcraft structural scale and designing critical joints.
As part of the design process, structural assessment represents an important aspect in the development of new airand rotorcraft. It plays a critical role in supporting the weight of the aircraft, transmitting loads from the rotors to the airframe, and ensuring the overall safety and integrity of the vehicle. The conceptual design phase is characterized by exploration and evaluation of broad design concepts, with minimal detail regarding structural design. In contrast, the preliminary design phase involves refining the chosen design concept and conducting more detailed structural analysis and optimization to prepare for the subsequent detailed design phase. In order to evaluate the airframe, the opensource based design environment PANDORA has been developed at DLR. This paper presents an overview of model generation, topology optimization, sizing, and crashworthiness aspects in PANDORA using validation examples and generic rotorcraft models.
As military organizations internationally assess life extension and replacement actions for current legacy helicopter fleets and next generation rotorcraft are under development, novel rotor system technologies are required to fulfill challenging low-speed and high-speed flight envelopes and mission requirements. Proposed by the Department of National Defense (DND) and in collaboration with the National Research Council of Canada (NRC), a TTCP AER CP13A.1 Collaborative Project (CP) has been initiated supporting multi-nation development of numerical methods for optimizing and designing next generation main rotor blades. Four NRC laboratories collaborated to assemble a data set comprising design, performance, aerodynamics, structures, dynamics, and flight sciences elements. Acquired through research and testing, this information provides reference, technical, and engineering knowledge to support aero-structural model definition, model output validation, and the numerical optimization process development.
This paper proposes a highly integrated 3-in-1 e-Propulsion unit that exceeds current state-of-the-art power density, utilising low-risk, high TRL technologies. The design process of the e-Propulsion unit is outlined, including the development of a high integrity, fault-tolerant system design targeting DAL-A safety levels. The resulting system concept embodies redundancy throughout the electrical system - two sets of windings in the motor and redundancy built into the power electronics create a robust and efficient architecture. The electrical machine is connected to an optimised single stage planetary gearbox to realise output shaft speed and torque suitable for an eVTOL or eCTOL type application. Both systems are cooled and lubricated by a standalone cooling loop.
The Advanced Helicopter Seating System (AHSS) was started as an effort to evaluate and improve the current state of military rotorcraft seating. The overall goal of the program has been to improve pilot ergonomics and safety through the integration of advanced energy absorption and vibration reduction mechanisms as well as a broad approach to system integration based around updated occupant anthropometrics. An entirely new seating solution has been developed, with intent to integrate with the AH-64 Apache platform for demonstration purposes. The AH-64 development culminated with a series of static tests and dynamic test events to measure the effectiveness of the safety systems integrated on the seat as compared to the legacy AH-64 seating system. While lumbar load data and seat stroke data was obtained, issues with the anthropomorphic test device (ATD) configuration at the 95th male configuration caused some data to be suspect, and premature failure of several components also caused loss of capturing accurate data. Lessons learned are documented in the conclusions. Data and lessons learned from this effort are being used to support a follow-on effort to develop a pilot seat for the UH-60 Black Hawk Platform.
An approach for redesigning the tip region of helicopter rotors to achieve a desired target pressure distribution is described. In this approach, the difference between the realized target pressure distribution and the target pressure values are used to drive the changes to the blade profiles. Because the design process is independent of the analysis that generates the surface pressure distribution, this approach may be used with a variety of analyses. Sample 2-D applications on the design of low drag rotorcraft airfoil sections are presented to demonstrate the ability of the design process to change the blade section profile iteratively and rapidly. The process is subsequently applied to the S-76 rotor to explore the redesign of the rotor tip region for improved hover performance.
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This Engineering Bulletin and its annexes provide guidance on the application of Human Engineering principles and practices to the analysis, design, development, testing, fielding, support, accident investigation, and training for military and commercial products throughout their intended life cycles.
The paper presents a methodology for sizing and preliminary analysis of Multi-Prop UAVs. The methodology is founded on design trends that emerge from a vast and unique database that has been collected for such vehicles. The database includes geometry parameters, components' weight, power required and flight performance estimation. For a given mission, the analysis enables optimization of a specific design of a Multi-Prop configuration for either minimal weight or minimal dimensions. As opposed to low-order and relatively simple analyses that are typically used in early design stages, the results presented in this paper include design trends and correlations within existing flying configurations, and therefore, contain many design constraints that typically emerge only during advanced stages of the design process.
With modern aerospace vehicle configurations, highly-coupled redundant flight control surfaces are becoming standard practice. For such vehicles, traditional System Identification (SID) methods may not accurately capture the individual contributions of effectors to the vehicle bare-airframe response. A Joint Input-Output (JIO) methodology was used to estimate the control power for each highly-correlated roll effector of the Bell V-280 hover configuration. The methodology was demonstrated using flight test data, where the identification results were compared to a high-fidelity hardware-in-the-loop simulation in the V-280 System Integration Lab.
Walter Rieseler was a German aeronautical pioneer, who initially was successfully designing fixed-wing aircraft, then was the first to invent an automatic feathering control mechanism for autogyros. Today he is mentioned in conjunction with the Wilford gyroplane, where his invention came to fruition. Back in Germany, he designed helicopters competing with the famous aeronautical pioneers Henrich Focke and Anton Flettner, until after his sudden death all activities ceased and his name fell into darkness.
The advent of the COVID-19 pandemic has created uncertainty and delays in procedures, but hospitals and surgeons still need a steady supply of product, meaning that the orthopedics industry must keep innovating. One thing is certain, 2020 will be a turbulent year for procedure demand. Early on, analysts predicted that because many orthopedic procedures are elective, they would be postponed to help free up space for critically ill patients. While the recovery of orthopedic procedures has begun more quickly than analysts initially expected, it seems likely it will take longer than expected to reach full recovery as we look into 2021. June ordering patterns were already much higher than May, but the quicker recovery may indicate a second decline (W-shaped) versus a sharp decline followed by a quick recovery (V-shaped).
Today’s medical device manufacturers are facing changing and more challenging requirements for their products. Users are demanding less-invasive devices, and in some cases, wearable devices that are robust and long lasting. Regulations are becoming ever more stringent and costly, especially in terms of biodegradability. Yet at the same time, device manufacturers want to meet user demands by including the latest technologies, while keeping their costs under control.
Over the years, technological innovation has allowed the medical equipment sector to become a mission-critical part of the healthcare industry, delivering such benefits as lower operating costs and improved patient outcomes. But competitive pressures are driving the need for device developers to provide a richer experience for users, incorporating broader capabilities and features and more options.
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