"Project Start to Baseline review
- Analysis of given canopy design and interface status from AH
- Development of canopy concept with higher integration and innovative manufacturing concept.
- Definition of tooling and layup concept
- Component testing for FEA material property validation
- Canopy design in compliance with the SSS and technical design requirements
- Interface definition of adjoining components incorporated and defined
- FEA bird model validation for CS29 bird strike simulation
- FEA stress analysis (operating load cases, bird strike, misuse load cases)
- Weight and CoG analysis
Baseline review to PDR
- Detail design of Canopy structure in compliance with the SSS and technical design requirements
- FEA optimisation of laminate structure for all load cases
- Further detailing and harmonization of interface definitions
- Detailed sizing hypothesis and model validation
- Weight and CoG analysis
- RC compliance analysis
- Quality and configuration management plan
Result: PDR passed with open actions
PDR to CDR
- Detail design of Canopy structure in compliance with the SSS and technical design requirements
- FEA optimisation of laminate structure for all load cases (static and dynamic)
- Manufacturing of test parts for bird strike tests
- Create and finalised SSDD
- Create stress substantiation report
- Specify manufacturing process and harmonize with AH
- Define materials and supplier
- Prepare documentation of all manufacturing steps
- ECO Design Report: Upstream LCA
Result: Fastcan held the CDR, closed all major actions until end of reporting period and passed the CDR successfully
- Tooling drop data released on the 21.06.19
Final Period:
KLK Motorsport finalised the design of the canopy structure after the CDR. All required load cases were simulated with FEA and the canopy material lay-up optimised accordingly.
For all carbon fibre parts (Canopy, Nose shell, Radome and Longeron) lay-up manuals or ply books were created which describe each individual ply for the manufacturing process.
Additionally, manufacturing drawings for individual components were created where appropriate.
KLK Motorsport prepared and delivered the required SSDD (System/Subsystem Design Description) and FMECA Report to AH.
An extensive, 250-page stress substantiation report was written documenting and summarising the evaluation and optimization of the canopy and the front fuselage for the CS2 Racer program.
This document, together with the DDP (Declaration of Design and Performance) was the basis for the successful permit to flight approval by AH.
Gerg M&F was responsible for the desing and manufacturing of the tooling and for the manufacturing of a flight worthy front fuselage in a ""Ready to assembly"" condition. During PDR and CDR GERG was supporting with concepts to ensure the producability of the front fuselage.
After the Tooling drop data release on the 21.06.19 the main work for Gerg M&F started. Gerg M&F manufactured all jigs, tools and parts in its facilities in Hohenthann Germany.
With regards to our exploitation plan, we, as FastCan, would have liked to exhibit a mock up canopy on a fare and/or present our findings during a conference.
Unfortunately for one, the COVID situation changed all that and for our part, our budget was already critical. We therefor decided to invest all our energy and remaining budget into the development, permit to flight documentation, manufacturing support and the manufacturing of the flight worthy canopy structure."
