Rose Project Highlights
Duration: Fall 2022 – Spring 2023
Tools Used:
- SOLIDWORKS for CAD design
- Foam board and 3D printing for material prototyping
- Aerodynamics principles for design and testing
Project Summary:
Project ROSE was an RC aircraft initiative aimed at building a long-range unmanned flight vehicle. It served as a practical learning experience to apply academic concepts such as statics, properties of materials, and mechanics. The project went through multiple iterations, utilizing foam board and 3D-printed components, with plans to incorporate composite materials.
Highlights and Insights Gained:
- Applied theoretical knowledge from coursework to real-world engineering challenges.
- Improved skills in iterative design and material testing.
- Gained experience in managing a project from concept to multiple iterations.
- Developed a deeper understanding of aerodynamics and RC aircraft design.
The use of 3D printing
Initial Use of Balsa Wood: The first iteration of the aircraft utilized balsa wood, inspired by the structural design of World War II era aircraft. This choice was influenced by its lightweight nature and ease of assembly, making it an ideal material for a team with limited CAD experience.
Over-Engineered Design: The balsa wood configuration featured a traditional spar and rib structure, but it was quickly identified as over-engineered for the aircraft’s size and weight requirements. The design included ribs and perpendicular stringers that added unnecessary weight, limiting the aircraft's performance.
Challenges in Transitioning to Composites: Although balsa wood was a practical starting point, it was not suitable for the intended move towards composite materials. The heavy, rigid structure would have complicated the transition, highlighting the need for a more adaptable design in future iterations.
Transition to Foam Board: We moved to foam board to explore the use of sandwich materials, which offered a better balance of strength and weight. The foam board cores provided a solid foundation while remaining lightweight and easy to work with.
Integration of Composite Materials: To enhance the structural integrity of the foam board, we began applying a thin layer of fiberglass composite material to the outer walls. This approach gave us stronger wings without significantly increasing the overall weight, making the design more efficient.
Lighter and Stronger Wings: The new foam board wings, despite being nearly half the weight of the balsa wood variants, were able to withstand the same loading conditions. This shift marked a significant improvement in our design, combining reduced weight with enhanced durability.
Exploring Composite Materials: Although we didn’t fully implement composite materials, we started developing a methodology for their use, particularly focusing on how to incorporate them into our design. The goal was to enhance the structural integrity of the aircraft further while keeping the weight minimal.
Fiberglass Infusion Method: We successfully developed an infusion method to create the external housing of the airfoil using fiberglass. This process showed promise for future iterations, where we planned to apply the same technique with carbon fiber for even greater strength.
Project Pause: Unfortunately, this phase coincided with the point where the project had to be paused. While we didn’t get to fully realize the composite materials’ potential, the groundwork was laid for future development.
Rose Project Summary
After becoming the president of the engineering club at Foothill College, I started Project ROSE to provide a platform for students to apply concepts from our engineering coursework in a practical setting. The project's goal was to design an autonomous aircraft capable of long-range flight, targeting a distance of 100 miles without the need for refueling or recharging. The project started with a small team and eventually grew to involve up to 15 students, with a core group of around seven consistently working on various elements of the aircraft.
The design process underwent multiple phases, starting with the use of balsa wood, then transitioning to foam board, and finally exploring 3D printing and composite materials. The move from balsa wood to foam board was driven by the need to reduce the aircraft’s weight, which allowed us to achieve a lighter and more efficient airframe. Foam board also provided a better platform for integrating composite materials, enabling a stronger and more structurally sound design without the need for internal spars. The transition to composites was aimed at further enhancing the aircraft’s structural integrity while keeping it lightweight, with the ultimate goal of doubling the airfoil's size.
One of the unique design elements was the twin boom inverted V-tail configuration, chosen to optimize weight distribution and reduce the overall size of the aircraft. While the project was less about technical achievements, it served as an essential educational tool. It allowed us to explore aerospace technology basics and apply what we learned in our physics and engineering courses in a real-world context. The project also provided valuable experience in utilizing CAD software, such as Onshape and SolidWorks, and in understanding key aerospace principles like static and dynamic stability, wing loading, and efficiency calculations.
Beyond the technical lessons, Project ROSE was a significant milestone in my development as a leader. It taught me how to manage a complex project with multiple teams and elements, honing my skills in team coordination and time management. Although the final iteration of the project never took flight, it laid a strong foundation for future projects and teams. It also emphasized the importance of understanding the science behind aerospace engineering, including aerodynamics, lift, and stability, all of which are crucial for my continued growth in the field