Project Overview
Objective: Design, fabricate, and test an RC aircraft capable of completing the SAE Aero Design competition missions. The team’s goal was to create a lightweight, wood-based airframe with optimized lift-to-weight efficiency while ensuring structural stability through finite element analysis and aerodynamic simulation.
As part of the University of West Florida’s SAE Aero Design team, I contributed to the design, analysis, and manufacturing of our competition aircraft. The project emphasized aerodynamic accuracy, strength-to-weight optimization, and manufacturability using laser-cut balsa and plywood components.
Design and Engineering Process
The aircraft was fully modeled in SolidWorks, with each part designed to be laser-cut from wood sheets for fast and consistent assembly. I developed both a detailed 3D CAD model and a 2D flattened version used for the laser cutting process.
I performed Finite Element Analysis (FEA) using ANSYS on the fuselage and wing baffle structures to validate stress levels during maximum load conditions. The baffle, critical for load transfer between the wings and fuselage, was designed and optimized to minimize deflection while maintaining a lightweight structure.
- Software Tools: SolidWorks, ANSYS, XFLR5
- Materials: Balsa wood, birch plywood, carbon fiber spars
- Manufacturing: Laser cutting, epoxy assembly, weight balancing
Aerodynamic & Structural Analysis
Using XFLR5, I analyzed the aerodynamic forces on the aircraft, calculating lift distribution and required wing loading across multiple flight speeds. This data was used to size the wing spars and baffle system before running structural FEA in ANSYS.
The analysis verified that the aircraft’s wooden structure could safely withstand flight loads and landing stresses. Results confirmed sufficient stiffness, with deflection remaining below the target 2% of span under full lift conditions.
My Key Contributions
- Performed aerodynamic analysis in XFLR5 to calculate lift, drag, and wing loading.
- Modeled full aircraft in SolidWorks and generated 2D files for laser cutting.
- Conducted FEA of the baffle and fuselage structure using ANSYS.
- Completed hand calculations for wing lift, airfoil sizing, and total aircraft weight balance.
- Assisted in assembly and ground testing prior to flight trials.
Gallery
Below are some photos from the design and fabrication process.
You can download the laser-cut layout file below:
📁 Download Laser Cut Layout (.AI)Project Documentation
The complete SAE Aero Design report includes detailed CAD models, aerodynamic analyses, FEA results, and testing documentation used to validate the aircraft design. You can view or download the full report below.
📄 View SAE Design Report (PDF)