• Introduction
• Structures
• Propulsion
• Aerodynamics
• Hydrodynamics
• Performance
• Stability & Control
• Ergonomics
• Systems
• Manufacturing
• Maintenance
• Cost
• Model

• Appendices 

• Main Page

The aircraft is constructed of a blend of composite materials, chosen for optimal use of the material properties.  Most of the fuselage utilizes a two ply fiberglass construction.  The outer ply is a typical, medium weight, woven fiberglass, and the inner layer is chopped and sprayed fiberglass, commonly used for boat hulls.  This arrangement allows structural features to be molded into the hull and significant cost savings over entirely woven fiberglass, while experiencing only a slight reduction in strength properties. 

Most internal structural components are composed of carbon fiber.  These assemblies utilize flat, pre-cured sheets of pre-impregnated carbon fiber honeycomb sandwiches cut from templates.  The wing and tail aerodynamic surfaces will also be made of carbon fiber, but in a co-cured, monocoque structure for strength and cost savings.  Due to the high capital cost of autoclaving, these assemblies will be sub-contracted. 

The assembly of this aircraft utilizes an efficient combination of serial and in-situ processes.  Production is divided into thirteen major sub-assemblies, such as landing gear, fuel system, and window molding.  The sub-assemblies employ serial processes, and just-in-time production is controlled through the use of an interactive computer inventory system.  The main assembly is the primary in-situ process, into which all sub-assemblies are fed.  Facilitating the main assembly, the majority of sub-assemblies use interlocking and self-aligning tooling. 
Innovative tooling fixtures were devised to manage the assembly of the aircraft and improve cycle times.  The bulk of the tool fixtures are used in the fiberglass and carbon fiber molding processes.  These fixtures use a number of innovative interlocking and self-aligning joints which assist in handling and joining of assemblies.  Bonded joints exclusively replace standard riveted joints to simplify assembly.  The mold fixtures have been designed for incorporation of vacuum bagging if increased strength properties are desired. 

 A facility layout (Figure M.5.2, Appendix M) and production plan was developed to illustrate how this aircraft is manufactured.  The two main goals in developing the layout were to minimize material handling and to maximize worker efficiency.  Smooth and direct material flow lines between workstations decrease workpiece handling.  Personnel requirements are fully addressed and optimal locations for the facility are noted in Appendix M. 

The facility accommodates four production lines which attain a production rate of 200 aircraft per year and is capable of handling an increased production rate.  Each aircraft requires one week to build.  No two aircraft will be finished simultaneously because production is staggered across the four production lines.  The facility has a number of unique and cost-saving features including an interactive quality control system, a small parts department, and a near-water site for take-off and landing.