Project Details
Designed and built a performance-optimized glider using carbon-reinforced foam components to meet strict dimensional (≤ 4ft x 4ft x 1ft) and weight (< 2 kg) constraints. The project followed a full aerospace engineering lifecycle, including design exploration, aerodynamic sizing, CAD modeling, and theoretical performance validation. The final airframe combined a high-aspect-ratio wing with a streamlined fuselage to balance glide efficiency with structural robustness.
Key features include a low-Reynolds-number SD7037 airfoil for laminar flow stability, a calculated glide ratio of ~40:1, and tail volume coefficients selected for optimal longitudinal and directional stability. The design process incorporated multiple airframe concepts, including inspirations from ASH-30mi and Swift S-1, which were ultimately hybridized into a custom configuration. Structural sizing, CG analysis with/without payload, and lift/drag estimation were carried out manually and validated against expected flight behavior.
All major components were 3D-modeled in Siemens NX, and material selection favored lightweight polyurethane foam reinforced by acrylic elements. The predicted unpowered glide range was ~64 meters from a 1.5-meter drop, with no propulsion or stored energy used. The entire project was conducted under NASA-inspired systems engineering principles, with documented roles, reviews, and testable performance metrics.
Bill of Materials (BOM)
The following table lists the components used in the prototype, including part numbers, quantities, materials, estimated costs, and potential suppliers.
Item | Component | Part Description | Qty | Material | Cost (USD) | Source / Notes |
1 | Wing Core | High-aspect foam wing panels | 2 | Polyurethane Foam | $20.00 | Cut to shape, reinforced internally |
2 | Fuselage Block | Streamlined center-body structure | 1 | Polyurethane Foam | $15.00 | CNC trimmed for balance |
3 | Tail Surfaces | Horizontal and vertical stabilizers | 2 | Foam & Acrylic Rods | $10.00 | Custom dimensions based on stability ratios |
4 | Structural Reinforcements | Spars, ribs, joints | 6 | Acrylic | $12.00 | Support load transfer at critical joints |
5 | Adhesive (structural) | Foam-safe epoxy | 1 | 5-min Epoxy | $6.00 | Used for key bond locations |
6 | Payload Compartment Housing | Box enclosure embedded in fuselage | 1 | Plastic | $5.00 | Houses 43g payload (4” x 3” x 5”) |
7 | Surface Finish | Sandpaper + surface treatment | 1 | N/A | $3.00 | Polishing for reduced surface drag |
8 | Paint Marker for Visibility | Wing and tail edge markings | 1 | Acrylic Paint | $2.00 | Non-reflective coating |
Data & Control System (Non-Physical)
No onboard electronics or actuation were used. However, MATLAB scripts were utilized to:
- Calculate Reynolds number, lift and drag forces
- Predict glide ratio and range
- Analyze center of gravity shifts with payload
- Estimate stability coefficients (horizontal and vertical tail volume ratios
These analytical results guided the component sizing, aerodynamic shaping, and balance decisions in the final CAD model and prototype fabrication.