SAE Aerodesign East: DJS Skylark

As a team, DJS Skylark adopted an iterative design methodology focused on achieving peak performance through continuous analysis, testing, and refinement. As the aero head, I played a key role in guiding the aerodynamic development of the aircraft. Here's a breakdown of our process:

1. Defining Our Goals: We began by setting clear goals, including minimizing empty weight and maximizing payload capacity, with a target to carry over 50 lbs.

2. Analyzing the Competition: We examined past competition results and scoring metrics to pinpoint key areas for improvement and strategic decision-making, such as optimizing luggage weight per passenger to maximize our score.

3. Initial Prototyping: We developed an initial prototype using a CH10 airfoil, specifically targeting our empty weight goal.

4. Airfoil Selection and Flow Analysis: Recognizing the critical role of airfoil performance, I spearheaded the selection of the S1223RTL airfoil. This decision was based on extensive CFD (Computational Fluid Dynamics) analysis, where we prioritized its high lift coefficient and reduced flow separation in 3D flow conditions. My direction here was crucial in shaping the aircraft's aerodynamic characteristics.

5. Iterative Refinement and Analysis: We continuously refined our subsequent prototypes, incorporating the S1223RTL airfoil and structural enhancements. Ongoing testing and analysis, guided by my expertise, allowed us to optimize performance while balancing weight and structural integrity. We focused on addressing flow separation and minimizing induced drag.

6. Trade Studies and Optimization: I oversaw the trade studies to evaluate various factors, such as airfoil selection, wing planform, and luggage configuration, striving for the best possible flight score.

7. Ensuring Structural Integrity: We conducted structural analysis throughout the design process to guarantee adequate strength while maintaining a safety margin below 0.2.

8. Prioritizing Drag Reduction: Acknowledging power limitations, we placed significant emphasis on drag reduction to increase velocity and, consequently, lift. I championed the adoption of aerodynamic covers and Hoerner tips to minimize drag.

Our methodology hinged on a continuous cycle of design, analysis, manufacturing, testing, and optimization. My leadership as the aero head helped drive the aerodynamic design to achieve the desired performance within the competition constraints.

As aero head on a team of 30 students, the SAE Aero Design project was a significant project management experience for me. It demanded seamless integration of aerodynamics with structural, avionics, and manufacturing aspects, and the attached document is the design report. Our key project management strategies included:

1. Cross-Functional Teams: Departments (avionics, structural, aerodynamics, marketing) collaborated closely, ensuring design decisions didn't negatively impact other areas.

2. Clear Roles and Responsibilities: Each team member had clearly defined roles and responsibilities, fostering accountability and ownership. 

3. Iterative Design Process: We followed a phased approach with monthly cycles of design, testing, and optimization. This iterative process, which began in July 2018, allowed us to identify and address potential issues early in the development process.

4. Cost Management: We carefully managed our budget by sourcing materials from wholesalers, seeking sponsorships, and organizing fundraising events. 

5. Risk Management: We identified potential risks, such as manufacturing delays and component failures, and developed contingency plans to mitigate these risks.

6. Schedule Management: We used a detailed schedule to track progress and ensure that we met our deadlines. As aero head, I coordinated with other team leads to ensure that the aerodynamic design was completed on time and integrated with other subsystems.

7. Communication and Documentation: Regular team meetings, progress reports, and design reviews facilitated effective communication and knowledge sharing. We maintained detailed documentation of our design decisions, analysis results, and manufacturing processes.

8. Fundraising: We organized an annual aeromodelling workshop in September to raise funds. I actively participated in the fundraising efforts, which significantly contributed to our financial resources.