project-highlight-image

Wing Spar Structural Analysis and Material Optimization

hero-image

Nick Glenn

Project Timeline

Sep 2025 - Sep-2025

OVERVIEW

In this mini project, I analyzed the structural behavior of wing spar concepts to understand how geometry and material choice influence deflection, stress, and overall design feasibility. I modeled two cross-sections: an I-beam and a hollow square, and evaluated each using steel, 2024 aluminum, and titanium alloys. My work included building the CAD models, setting up the FEA simulations, and adjusting dimensions to meet the required deflection target. I began with a simplified uniform lift model and later incorporated a more realistic triangular distributed load with a concentrated engine weight, which revealed how complex loading drives significantly different design decisions. Although brief, this project further solidified my understanding of real-world engineering applications and the importance of material selection, mass, and manufacturability.

HighlightS

Built and parameterized CAD models for two complete wing spar geometries.


Ran FEA simulations across three materials and iteratively tuned dimensions to reach the 3–3.8 in deflection target.


Modeled both simplified and realistic aircraft loading, including a triangular lift distribution and engine point load.


Compared structural efficiency, weight, manufacturability, and cost for each design.


Determined that a titanium I-beam provided the strongest performance under realistic loading despite higher cost.

SKILLS

FEA SimulationCAD ModelingStructural & Material AnalysisEngineering Trade Study DevelopmentTechnical Communication
Home
Questions?
hero-image

Nick Glenn

Mechanical Engineering Student

I’m a mechanical engineering student at Cal Poly with a passion for design and understanding how things work. My experience spans aerospace, mechanical design, and manufacturing projects, from industry work with Northrop Grumman to on-campus lab research focused on minimizing wing spar deflection. Through these projects, I’ve developed hands-on skills in CAD modeling, FEA, CNC and lathe machining, and 3D printing. I enjoy the rigorous path and solving complex problems both in academia and the real world.

| lowinertia |
Engineering Portfolio in 15 minutes
Create Your Portfolio