Hey, Leon! Been a minute. So I've benefited a lot from your videos and thought perhaps you'd find a contribution useful, here. I'm a design engineer who's building a plane of his own, so I've taken your wing profile (from screenshot) and created a topological optimization simulation for it in ANSYS. There are some big caveats involved, like the fact that it uses a uniform distribution of load, for simplicity, and the fact that it is based on a flat sheet, rather than your more optimal deformed sheet metal, but the results should be (qualitatively) valid, and could be used to inform a future truss model if you wanted. In my validation simulations, this geometry was able to support your 112lbs using a flat sheet thickness of .35mm Aluminum, which had a mass of 40 grams. Formed sheet metal would be stronger, of course. Were I making this part myself, my next step (after refining my load conditions more) would likely be to simplify the profile I've pictured for manufacturability, before regenerating the model and doing further simulations, then moving to prototypes. Given the results I'm seeing, I'd be considering using tension members (probably dyneema cordage) for the upper supports. If you do use these results, please note that the dark blue areas are where there is still very little strain in those members, and they could, in some places, be skeletonized considerably more. Please let me know if you've any questions, and I hope you find it useful! -Ryan drive.google.com/file/d/16_yYe4do4LbOqGwBrWVQejduV_6qclEg/view?usp=drive_link
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Well done video, great presentation.
The only real test that needs to be applied in connection with any "ultralight" is whether your life insurance policy is paid up.
Hey, Leon! Been a minute. So I've benefited a lot from your videos and thought perhaps you'd find a contribution useful, here. I'm a design engineer who's building a plane of his own, so I've taken your wing profile (from screenshot) and created a topological optimization simulation for it in ANSYS. There are some big caveats involved, like the fact that it uses a uniform distribution of load, for simplicity, and the fact that it is based on a flat sheet, rather than your more optimal deformed sheet metal, but the results should be (qualitatively) valid, and could be used to inform a future truss model if you wanted.
In my validation simulations, this geometry was able to support your 112lbs using a flat sheet thickness of .35mm Aluminum, which had a mass of 40 grams. Formed sheet metal would be stronger, of course.
Were I making this part myself, my next step (after refining my load conditions more) would likely be to simplify the profile I've pictured for manufacturability, before regenerating the model and doing further simulations, then moving to prototypes. Given the results I'm seeing, I'd be considering using tension members (probably dyneema cordage) for the upper supports.
If you do use these results, please note that the dark blue areas are where there is still very little strain in those members, and they could, in some places, be skeletonized considerably more. Please let me know if you've any questions, and I hope you find it useful!
-Ryan
drive.google.com/file/d/16_yYe4do4LbOqGwBrWVQejduV_6qclEg/view?usp=drive_link
Very cool. Thank you for the work that you've done.