Designing an aircraft is unlike assembling a kit airplane. No one is supposed to create their aircraft. Considering the complexity and safety operational risks, it is a job best left to an experienced professional or (better still) a team of experts. Regarding aircraft design (even the ultralight single-engine variant), aerospace engineers are your best bet for the undertaking. Aerospace engineering services have what it takes to design and develop an aircraft, build a prototype, and conduct all the necessary tests to ensure everything functions as intended. In an aircraft design project, parts of their responsibilities include:
- Analyze a project proposal to determine whether it is technically feasible
- Oversee the design process as well as parts production and testing procedures
- Determine design constraints, safety risks, and mitigation methods
- Develop quality and completion requirements
- Evaluate the design process to make sure everything is according to environmental regulations, safety standards, engineering principles, and client requirements
- Perform thorough inspections for technical issues and parts malfunctioning and identify the problems
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An aerospace engineer may engage in a particular specialization related to aircraft or spacecraft design, for example, aerodynamics, navigation systems, communication technologies, instrumentation, structural design, control, propulsion, combustion, or robotics. In addition to aircraft and spacecraft, the profession covers missile designs and satellites.
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Aircraft design cost
There is no single one-size-fits-all dollar value for aircraft design. Suppose you are using the average salary for an aerospace engineer in the United States. In that case, you should pay around $122,270 per year or a rate of $58,78 per hour. Assuming it takes five years to build a ready-to-make design, the service will cost you $611,350 to cover the engineer’s salary. However, it is only sometimes that simple because designing an aircraft is multidisciplinary. The profession is divided into two major categories based on the qualifications:
- Aeronautical engineers – their primary job is to design aircraft and propulsion systems of the vehicle. Their work also involves studying and implementing aerodynamics and aircraft construction materials.
- Astronautical engineers – the professionals who deal with the technology and science of spacecraft. Many of them work on satellites deployed outside of the Earth’s atmosphere.
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While it is clear which professionals to hire, there are further specializations in the aerospace engineering profession based on the industries. Each specialization comes with a different annual salary as follows:
| Job Divisions | Annual Wage |
| Research and development | $128,020 |
| Aerospace parts and products manufacturing | $126,780 |
| Control instruments, electromedical, and navigational devices manufacturing | $121,530 |
| Engineering services | $120,640 |
Considering the multidisciplinary nature of aircraft design tasks, you might need to hire at least one aerospace engineer from each specialization. If an aircraft design is done in 5 years, complete with all flight and systems tests, the numbers total $2,484,850 – again, only for the engineers’ wages. Believe it or not, the certification fee alone for small aircraft ranges from hundreds of thousands to millions of dollars. A budget in the neighborhood of $3 million (not an exaggeration) might just be enough to get a certified aircraft design.
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Aircraft design process
While an aircraft design process only consists of three major phases, there are subsequent procedures for certification purposes.
- Conceptual and planning: like most design projects, the first step involves researching design requirements and specifications. It is the phase where design engineering firms determine the preliminary configuration and propulsion system. All parameters defined must be based on the type of aircraft in question. It can be an ultralight model, a primary aircraft (with three or four seats), general aviation, or a commercial model. Planning may include cost estimation work, too.
- Preliminary design: The conceptual design is refined and optimized to conform to design parameters. Engineers must define the proper methods for fluid dynamics calculations and wind tunnel testing for a brand-new design. Configuration layout is further improved to ensure all major components (such as fuselage, wings, landing gear, propulsion system, control, flaps, and stabilization) are well integrated. Engineers must also perform structural analysis for flaws or defects and correct the issues before preparing the design for a flight test.
- Detail Design: This is the phase where engineers use all the components and technologies prepared in the previous steps to build an actual working aircraft. The finished design must achieve the pre-determined requirements of structural integrity, system integration, aerodynamics, and performance.
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The last phase is also the lengthiest, as it will include flight simulation and real-world analysis of the aircraft. Finite element analysis professionals test every single component and analyze it for mistakes. Since a flight test is complex, having multiple engineers oversee the procedures and provide reports is best. A full-flight simulator can thoroughly test the overall aircraft design, including controls and flight dynamics under various simulated environments. That said, a real-world performance test is still required. A flight test shows whether the aircraft can fly and its performance under rigorous stress (such as vertical maneuvers) and excessive load. Significant concerns are on the following components and factors:
- Wing design
- Fuselage design
- Tail design
- Propulsion system
- Landing gear
- Weight distribution
- Stability and performance
- Equipment and system integration
A flight test is not meant to be a one-step process. A new aircraft design may undergo multiple tests and refinements to improve functions, performance, and stability. It may take years to complete. In between every flight test, there is a “Critical Design Review” process where engineering design firms make small or significant changes as needed based on test results.
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Aircraft certifications
There are two types of aircraft certifications (in the United States): MIL-STD for military aircraft and FAA (Federal Aviation Administration) for civil aircraft. The certifications are divided into three categories:
- Type certifications: approval of aircraft design and components. A type-certified model means the design complies with airworthiness, exhaust emissions, and fuel venting standards.
- Airworthiness certification: a stand-alone airworthiness certification signifies that the aircraft design is safe for operation.
- Production certification (for manufacturers): FAA approval to duplicate the design (manufacture the aircraft) by the specified type. A certified manufacturer has the facility, personnel, and systems to produce an aircraft that conforms to the approved design.
All countries or regions have certification boards with specific Technical Standard Orders (TSOs) sets. For example, Europe has the European Aviation Safety Agency (EASA) to enforce TSOs. Once certified, the aircraft can move forward to production, enter the airspace, and have full utilization.
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Manufacturing and disposal
A prototype is not the final version, as some changes might be implemented following flight tests and the certification process. Now that the technicalities have concluded with certifications, the aircraft can be manufactured and delivered to the client. For the first flight, the client is often accompanied by support personnel to provide guidance, warning, and general instructions.
Similar to all hardware and technologies, there will be a time when the aircraft design meets its end of economic and operational life. A good design process should cover such an inevitability. Engineers devise a plan or method to destroy or dispose of the materials properly.
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Aircraft design constraints
Aircraft design projects always have three primary constraints: purpose, regulations, and budget. There might be other technical and non-technical challenges during the design process, but those three are integral.
- Purpose: the intended use of an aircraft limits engineers’ freedom. For example, commercial airliners must be designed to carry a massive load of passengers and be fuel-efficient. In contrast, jet fighters must perform physics-bending maneuvers and sometimes execute stealthy attacks. Passenger aircraft should not burn fuel and can be as spacious as required as it is commercially feasible. On the other hand, jet fighters must be light and compact to be nimble. Some designs are built for a specific environment; for example, an amphibious aircraft features unique landing attachments to stay stable on dry land and water. There are also aircraft equipped with vertical take-off and landing (VTOL) and hovering capabilities. Each purpose presents a different set of design requirements and constraints.
- Regulations: without an authoritative body to enforce regulations, aircraft designs may pose safety risks to pilots, passengers, and other vehicles. A new aircraft design must meet strict rules and airworthiness standards to minimize the possibility of accidents or communication interference. For example, some airports dictate that an aircraft should not exceed a maximum wingspan of 80 meters to avoid collision when landing/taxiing.
- Budget: the most obvious constraint is budget. In short, aerospace engineers must work within the pre-determined financial resources to build an aircraft according to the client’s requirements. The general wisdom is that aerospace engineers design the best aircraft using as little money as possible. It does not mean a design must be cheap; it must only be efficient and functional.
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Designing vs. assembling an aircraft
Designing an aircraft is unlike assembling a kit airplane. Building a kit aircraft is quicker, easier, and less demanding overall. However, creating is not a design work because all the parts and components have already been prepared, including the engine, instruments, and exterior bodies. With most kits, you buy pre-made parts and then assemble them into a working aircraft. You may find an engine, propeller, avionics, upholstery, instrument panels, and even paint inside the kits.
How Cad Crowd can help
Navigating the intricate world of aircraft design requires precision and knowledge, and understanding its associated pricing can be equally challenging. Cad Crowd is here to illuminate the complexities of aircraft design services, offering an in-depth analysis of pricing, rates, and costs tailored for businesses.
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