Exoskeleton wing design - how carbon fiber makes it possible
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- čas přidán 14. 07. 2024
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The wing of the DarkAero 1 is strong enough to support thousands of pounds of lift load while remaining exceptionally light. Part of the secret behind this is it's made from carbon fiber composite. However, there's more to its structure than meets the eye. In this video, we discuss the design of the composite structures inside the wing of the DarkAero 1 and what makes them different.
0:00 - Intro
0:18 - Design Requirements
1:51 - Lift Load Distribution Defined
2:57 - Conventional I-Beam Wing Spars
6:11 - The DarkAero "Hollow Grid" Approach
7:32 - Advantages of "Hollow Grid"
8:52 - Advantages of Using Composites
10:15 - Physically Test or Simulate?
11:40 - Summary
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Im curious will yall have a jet engine variant in the future like Sonex has done?
We must be getting close to take off.
Very impressive lecture. When you performed the load testing of the complete wing, even though the wing withstood the load, how do you know if internal damage has occurred ? Do you have inspection hatches/ holes to enable say fibre optic visual inspection, or are there other NDT testing methods available….strain gauges, ultrasound etc…
Inevitably the wing will experience stress/strain reversal which in an Al structure will lead to fatigue, do these composite structures delaminate ? How do you plan to verify the structural integrity while in service ?
I really like your project and your videos. As a mechanical engineer myself I like your factual, no marketing bullshit approach to your videos and also to your product itself. A breath of fresh air in the "sell pie in the sky" startup world.
Haha, yeah, no battery electric powertrain. I guess the long range requirement killed that in the first 5 seconds of analysis.
I would agree. Engineer here too.
I mean this as a huge compliment. In your next life you would make a fantastic Mechanical Engineering Professor. You have the rare ability to explain complex concepts in an easy to understand presentation. Thank you.
The methodology you guys practice in researching, building and testing parts is really impressive.
Extremely good and concise presentation of the right way to do wing design! Can’t wait to see her fly!
Yes, this team is a breath of fresh air. Let's hope they do well after all their effort.
I was always curious about the solid foam core vs hollow composite wings. Cool to see you guys came up with your own unique solution
I can’t stop looking at that beautiful carbon fibre 😍 fascinating discussion about why you’ve made the choices you have, and how it benefits the design.
Excellent content and presentation, guys! You all have great skill at not only highly technical processes but also the ability to convey it down to our level without coming across as condescending or droll. Congrats! keep them coming!
Terrific instruction. Clear, concise. Your flow is clear. You anticipate questions. Thanks.
Great to be able to come along on your journey. Thank you for the big effort you are putting in to share your story and educate us along the way. Very exciting project! Cheers from Sydney - Dave
I started watching these, because I just love fast and efficient aircraft.
However, these videos provide such an in-depth insight into composite manufacturing that my engineering interest now benefits more from it than my passion for flight 😄
Wow, so well explained, detailed and concise. Love the idea that you don’t need mould so you can change the design quick and easily.
Kudos. You guys are so professional and so generous with your time in sharing your knowledge and vision. If I was 40 years younger I would beg to work with you.
I really, really, really like that you guys are product-focused and engineering-centric. That takes care of marketing by itself, as opposed to others "sell impossible performance first, figure out how to make it close-ish enough that you are not sued later" like the Raptor fiasco.
Awesome follow up to the last video on wing design. Loved learning about the thought process behind Hollow Grid, in depth. Great stuff!
"Structural Divergence" is suddenly my favorite way of saying the wings broke off.
Add to that “thermal excursion” as a way to say the airplane started on fire.
Just amazing, thank you so much! I don't recall ever been that captivated for something that technical before
Excellent damage tolerant design. Multiple load paths reduce the risk of single point failure. You explain complex engineering principles in a direct, easy to understand manner.
Nice video!
I'm curious to see how the fueltank works with so many compartments.
I think it's essentially gravity drain through interconnected compartments and a large reservoir between the wings to collect before sending to the engine fuel lines.
They act as natural baffles.
I'm with you, would like to see the fuel tank design, seems like you would need a lot more sealant, which would mean more weight.
@@divyajnana More sealant for what?
@@divyajnana Watch their videos from beginning to end and you will then know what you didn’t before. 😉
You guys are absolutely killing it
It's always nice to see machines being built as embedded thought, taking maximum advantage of the properties of the materials. Relates to "Zen and the Art of Motorcycle Maintenance.
This is interesting. Love to know more about the testing and simulation, in particular higher energy dynamics, heating, impact, electricity, etc.
Your comment about testing vs simulation is so very true and ultimately important. Simulation is only as good as the data that's entered and all too often what's thought to be complete has omissions. Empirical data from testing will fill in the simulation gaps and keep you and your passengers safe. Thanks for the video and explanation.
Absolutely love watching your new videos. Can’t wait to see this thing fly. 🎉❤😊
On the manufacturing topic, could you give us some insight into how the hollow grid is bonded to the skin? Specifically how you can count on that in a tank application..
Love these videos, incredible content.
Great job guys!!!
Agreed, love the innovative ideas and think this is brilliant for things like control surfaces. But have to admit I am skeptical of that being used as a tank. There is a whole lot of bond area there and if any bit of it fails it will both leak and be inaccessible for repair.
Fantastic video! Being a traditional aluminium construction kinda guy, this was extremely educational. Looking forward to the next one already.
Big Burt Rutan fan here. This generation it’s Dark Aero. Nicely done fellas.👍🏽👍🏽
Fantastic video! Thank you for sharing!
Brilliantly concise explanation!
I always look forward to your new releases. These videos are great for educating and building confidence in your design. I’ve always wondered however why are you teaching building classes to people who are not necessarily interested in building your aircraft?
Diversified income, fresh ideas brought up by students, future employees...
This channel is a Gem for the engineering community, it doesn't has to be applied on building specifically their aircraft in order to be useful for us. Knowledge is always useful
For the same reason you and I watch their videos
This was incredibly well explained and you're a very good speaker! I'd heard of the DarkAero but wasn't really following it, I watched this out of pure engineering curiosity. Definitely interested in hearing more.
I would love to know if you guys have been surprised by anything you've learned yet while building this very coot plane? Is there anything that you just didn't even think about or is the building and design process calculated to the last detail and you haven't been surprised by anything? Keep up the cool videos, I get excited when I see a new one.
Hi Paul! Thanks for checking out our videos and thanks for the great question. Yes, lots of surprising challenges popped up along the way. A big one was canopy manufacturing, which turned out to be much more involved than expected. We spent too much time on that before we ultimately outsourced the process. We might try to bring it back in-house at some point. Making large honeycomb sandwich panels to meet our own standards turned out to be hard as well. We figured out how to do it at a small scale pretty quickly, but scaling it up was difficult.
Looking forward for the test flight!
Great content, well structured and presented! Excellent!
“well structured”…I see what you did there ;)
Fascinating. Love your guys work
Absolutely excellent video. Your methods and design techniques are very impressive.
Thanks for a very clear explanation. You're an excellent teacher. Definitely want to hear how you're building this. Subscribed.
Great content, love your clean whiteboard sketches.
Loving these videos, thanks for digging into the engineering
Brilliant work and excellent video.
You guys are amazing! Cant wait to see this fly.. 🙂
Great information, really enjoy the technical side of design.
Phenomenal video! I wish I had seen this one year ago before I designed the airfoils structure on our FSAE car. Going to pass this video on to my classmates.
Outstanding presentation and narration, clear, concise explanations of technical, engineering and fabrication matters. Subscribed.
Thank you for checking out the video! We appreciate the kind words too. :)
Designing and building a plane is pretty cool but the materials and structure knowledge your team has developed is even more impressive. Honestly, with your skills, you could probably be designing and building about anything!
Wow this is very interesting, thank you for your educational videos.
Awesome video once again guys !! Thank you 🙏
Amazing explanation!
not sure why Im watching this , but you sure make it interesting to see all you put into it. can't wait to see the final product.
Love this content. Thank you. I heard about galvanic corrosion problems joining carbon fiber to metal. So many issues. Great job.
I need one. Can't wait to place an order.
I really appreciate your hand drawn stuff.
Can’t wait for the manufacturering video, great video 👍
Another amazing and informative video! 👏👏
You finally answered my question with this video.
Great video guys, keep up the good work.
Love you guys. Because of you I can understand how to make a good design as a erospace engineer student
Another great video!
Apprendre comment construire son propre avion est bien . Compliments pour le cours très instructif
Lovely explanation!
Excellent presentation !
Thanks for sharing your work, it's really interesting!
excellent info and you manage to fit it all on one whiteboard!
Wow, Carbon Composite magic... Nice to see you in the future of aircraft being done this way.
Excellent presentation.
Damn your white board drawing/writing skills are good. Aesthetics for days.
Great approach to strength weight ratio
I love the videos. Would love to get some updates on testing. Like what's the progress, is there rough timeline for first flight, etc.
Great explanation, I undestood most of it and I'm not an engineer.
your presentation is getting better! Much more prone to keep watching; doesnt feel too slow as some have felt
Very intelligent engineering related to manufacturing simplicity. That was your biggest achievement. Smooth and deliberate presentation of information. I love the hollow grid design, it is more organic and this should be the direction taken psychologically with all engineering and architectural thought processes. Well done gentleman, I will take your course as it sounds like great FUN ! And it may give me new insight to precast, aerated concrete panels inlaid with an organic matrix. Thankyou.
That was a treat. Lately, I too am using carbon fiber (foam cored) sandich panels, CNC cut to manufacture the internal structure of an aircraft. I second that the benefits of that approach being no-tool, large stock, easy design change, are extremely undervalued.
I love this channel. You’re a bunch of nerds!! Thank you.
🤓 Happy to hear you are enjoying our channel!
really good stuff. thanks
Never before appreciated the nuance of an I-beam the way you describe.
Chances are low that i will build my own airplane (except a small one out of paper) , but i really enjoy your vids.
Very informative and a joy to watch.
Well done!
This is really sick stuff, innovative, different. Interesting thing I noted about y’alls hollow core concept is that something similar is has been used in some 3D printing RC airplane designs too, going as far as to place stingers at angles to the width span of the wings. Its all fascinating
A similar design is used in fighter jet wings also. One that comes to mind, is the F-104. Where compressed bleed air from the engine was sent outboard through the wing, and emerged from ports precisely located to blow air over the flaps when deployed. "Blown flaps" as they were called, reduced approach speeds significantly as long as the engine was kept spooled up and compressing plenty of bleed air. Losing the engine in this configuration, when landing, was unrecoverable. Such were the 1950s.
Fantastic. Very interesting. 🇨🇦
Excellent! I believe in all this.. 👏🏼
Thanks for sharing
Keep doing more educational videos ⚡🙏🏻
Thoughts about the very linear stress strain curve of carbon fibre? I am a structural engineer - in seismic engineering we use the non linear section of the stress strain curve (from yield to ultimate) to dissipate seismic energy (hysteresis - ie with steel ultimate strain is ~2.5x yield). This allows us to design for lower seismic force level and we intentionally let the building go non linear to dissipate energy - with the primary intent to prevent collapse (and the building is also not likely useable after a design seismic event).
In the high performance sailing world, I think this has been one of the fundamental issues with CF. They are hitting yield loads followed quicly by structural failure because of the lack of a yield plateau (there is no ductilty). Do not know how the aeronautical codes are written but IMO, use of carbon fibre probably needs higher factor of safety in comparison to say aluminum. With CF you basically cannot afford to go past yield...
Great video. I even knew some of the words.
good design!
Love the progress you guys have made over the years I’ve been following your project.
Great stuff 👏
Just a couple of questions :-
(i) - Have you evaluated fuel flow, migration and fuel bubble criteria for your ‘wet wing’ design ?
(ii) - Do you anticipate having to be able to inspect the internal spaces within the wing periodically and if so, does the ‘hollow grid’ construction make provisioning easier or more difficult ?
Looking forward to seeing you progress to a successful first flight and beyond 👍
Cheers,
dave
Dude you guys are Awesome.
I will E mail you shortly.
I like the term "structural divergence", reminds me of SpaceX's term "rapid unscheduled disassembly".
Awesome video, great explanation. How are you bonding the ribs/shear webs back to the skin with the distributed spar?
True Masters of your craft…No pun intended
G,day Riley, River and Keagan from Sydney Australia.
I was wondering how you design structures (aerospace). I knew the components; ribs, spars, struts etc. I now have a idea of testing to resist G force loading.
So... one could purchase plans with specified materials or "build and carry out testing to "with a coupon calculations measurement system recognised by the FAA"
On the other hand; completely experimental categories.
Then there's materials;
* Wood, fabric, aluminium, composite material such as fibreglass, carbon fibre in moulds etc.
"Speed, just a matter of money, how fast do you want to go?"
That was was a great lecture sir, you got my brain to spark on two cylinders.
🍏🇭🇲
So cool
Another good one! Whens the homebuilt engineering class start?
Good idea's
Can you imagine if the Write Brothers could have watched your videos how much easier building their first airplane would have been.
Interesting!
Fun topic. Would also love to see how the fatigue load test is designed and conducted. - formal aeronautical engineer.
Interesting concept! Was wondering how did you come to the conclusion about the weight saving of 10lbs? Great content as always well done
Great video, and you are selfless in what you share. Another reason we should be moving away from ribs and spars, is that they are an outdated function. They were needed to take mechanical loads when we had cloth wing skins! Now we have wing skins with serious stiffness/weight properties, we really don't need them so much! Yes theres shear to deal with and face collapse, but i love your design. Be really interested to know how you connect the cell spars to the upper wing skin when you close the structure, how do you know the glue is touching? :) Cheers from UK
Nice one guys, what you have achieved so far is brilliant! Keep it up!
Quick question:
How do you ensure that any ethanol content in the fuel does not attack the sandwich pannel epoxy exposed to fuel in the fuel tank?