Why So Many Parts? | DarkAero Shop Vlog | September 4th, 2021
ฝัง
- เผยแพร่เมื่อ 13 ก.ย. 2024
- Join the DarkAero Community - www.youtube.co...
(Exclusive members only content including photos, videos, live Q&A and more!)
Lately we've been working on CNC machining components for the main landing gear. Progress has continued on integrating the electrical system hardware into the fuselage of the DarkAero 1 prototype. We've also installed the wingtips to bring the wing of the aircraft close to completion.
DarkAero 1 Aircraft - www.darkaero.c...
DarkAero Knowledge Base - www.darkaero.c...
DarkAero Apparel - www.darkaero.c...
If you enjoyed this video and would like to see more of this type of content, follow along as we work to create the fastest, longest range aircraft you can build in your garage!
More information on DarkAero can be found on our website and other social media accounts:
www.darkaero.com
/ darkaeroinc
/ darkaeroinc
/ darkaero-inc
![[FULL EP.73] เปิดบ้าน 70 ล้าน "แป้ง Zbing" ยกมาทั้งญี่ปุ่น l เคหสถานบานปลาย l One Playground](http://i.ytimg.com/vi/YBnJhTt07Pg/mqdefault.jpg)
Thank you guys for spending time sharing DarkAero's advanced approach prototype progression. I enjoy spending my time with your channel!
Thank you Will! We enjoy sharing the journey and we appreciate you following along! 🚀
*MEGA GIGA* Great segment on drag links, etc. DA team is *engineering* great content. Very accessible to the casual viewer. Thank you!
Glad you are enjoying! One of our goals with this channel is to give a window into engineering and manufacturing. We think this stuff is cool and interesting so hopefully we are making it worth watching! 🤓
DarkAero updated! I’m psyched! Ah yes, the magic key-card tool!
Great update , this is the best aircraft design process on TH-cam.
It is coming together piece by piece. Looking great.
I’m definitely buying one, hurry up so we can hit the sky’s, you guys are awesome, the engineering is so meticulous and precise listening to fly like the wind I can’t wait to buy one I’ll meet you guys next year so keep up the good work I love it
6:47 "That's all hinging on..." as he stands over a half dozen hinged parts!
Good one! LOL!
that's one awesome build, loving these videos!
As always guys looking fantastic! Since Mike has finished his scrappy project, you guys are my go to channel for my much needed plane building fix!!! Just hoping one day I’ll be able to afford my very own dark aero to build...🤞🏼
Thank you for following along. We enjoy sharing the journey!
Great day when you brothers make us a video, true, but when it is machining a big YES, that is what we do an know so it is great to see how well you have utilized the Tormach into your component builds and doing it in-house is what we personally love to see, thank you take care. Lance & Patrick.
Congrats guys!
Project interesting, I like also keep actualized in each fase of this job.
Really appreciate these updates. So inspiring
A week long wait seems to eternity. Can't wait to see this beauty fly. 😍
I'll be finishing my aero degree from Delft in a few years. Hopefully once I get a job I could buy one of your planes!!
Fantastic to watch the progress. Keep it up guys. 🇨🇦
Please wear some more PPE when using that clickbond glue lads, it has the most terrifying list of organs it damages on the warning label 😂 definitely the worst stuff I think I've ever dealt with at work, aside from Alucrom anti-corrosion coatings
Totally agree on this one! We are typically very strict on our PPE use but we were clearly slacking in the glue up sequence in this video! Agreed as well on the dangers of corrosion protection chemicals for aluminum. I helped a friend do some of that on his RV-10 and the process required some serious PPE.
@@DarkAeroInc Thanks for the response guys, glad to hear it. Thanks for sharing this journey in such great detail and absolutely can't to see this thing soar!
I have a question. As an aerospace engineering student I am working on learning about design or aircraft. When you guys designed and built your wings did you reference NACA airfoils? If so what calculations did you go through to find the right balance of tilt, AOA, and scaling the wing? If not how did you come up with the camber and airfoil shape?
Thanks!! Keep up the awesome videos!
Great vid again. Sonex, Sukoi, Rocket and I believe Lancair IVs use titanium gear legs. If they work for them, they should work for you if weight is a concern. Far less parts, less expensive, less maintenance and probably lighter too.
Brilliant! Love your work and I'll keep watching your content.
WOW !!!! 🤩🤩🤩 Looks really great !!! Thx guys for your work,all we are really exciting the result and all we know it will be great and beautiful plane !!!Thank's a lot guys, really good job !!!👍😎🤙🛩️
I just got done watching every one of your videos in chronological order. I absolutely love them, I'm definitely excited to see the flight test.
Also DarkAero helicopter when? :)
Wow, that’s awesome! Glad you like the videos. :) We are extremely eager to get into flight testing as well. Something with vertical takeoff we be pretty cool for a future model, but for now we are keeping focused on the DarkAero 1. Thank you for following along! 🚀
@@DarkAeroInc
(edit) I love this project and your team's energy. Question: A common "hangar rash" is wing tip damage. What will the level of repair process complexity be for permanently bonded tips?
Personally I would never permanently bond in that wingtip.. one fine day you will need access. Sooner or later.
Hi Koncas! Thank you for following our project. If the tip needs to be replaced it can simply be cut off and replaced. We actually did this once with the tips on the HS because we made a design change at one point. The tips really shouldn’t need to be replaced though. They are quite solid once installed and should tolerate normal levels of bumps or tool drops. The access covers allow for maintenance of the wing tip lights, magnetometer, and pitot tube.
My question is who gets to test fly this OUTSTANDING aircraft? ,and thanks for sharing!
thanks a LOT a LOT this is priceless for who ask question onhow to do even if I will never do it, I wanted to know how
could you make a video talking about inserts used in cfrp?
Excellent build
Hi guys, will you be making provisions on the airframe for a BRS parachute system?
Love the outro/takeout :D
That clam-shell rudder is super slick. I remember the video about it but, I can't recall if you discussed the advantage of only outward facing hinges. Since the rudder panels don't cross the centerline, the hinge interface is completely flush. That must be great for your cruise efficiency!
Nice observation. I hadn't really considered that. But Split-flaps are known to be the lowest-drag flap in their retracted position.
Two years ago, i read a bunch of naca data on split flaps, plain and slotted flaps. I have no idea why engineers are so obsessed with slotted flaps, they only make +10% more lift than split type. (though about half the drag at small deflections). So, engineers of standard GA craft seem to like slotted for their low drag takeoff-flap setting. I now prefer split flaps, based on what I've read. (Simplicity, light weight, lowest drag, no drag making gap through the middle of the Airfoil, and airflow doesn't separate over the aft-top surface when deflected).
@@TheJustinJ then it doubles as a speed brake. It's amazing it's not more common.
That's interesting about how little extra drag it actually causes. Cheers.
@@FiferSkipper yeah, it's a clever design. As long as it's large enough that one can counter the engine torque and prop-factor at low speed and high power settings, without resorting to full-deflection. As this would create quite a bit of drag right when you don't want it; e.g. a crosswind go-around scenario.
Fuel under pressure in the cockpit is not a good idea.
Is there plans for bronze bushings an grease fittings for the drag link joints.
did you change t-shirt while making the 1st part?! Keep it up!
Question: Any reason for using a pitot tube as opposed to a pitot knife? Seems to me the knife is more compact, and seeing as you guys are so detail oriented, I’m sure you have a reason for using the tube instead. It’s be cool to know. Thanks for all the vids!!
The pitot tube we selected has an angle of attack sensor built into it, and it’s set up to work with the Garmin G3X avionics suite we are using.
DarkAero, Inc ahh gotcha. Am I correct in assuming that an angle of attack sensor is not available in a knife style pitot setup? i.e. A pitot knife would have been ideal, if not for the lack of angle of attack sensor and/or G3X compatibility? Thanks!
I've got a "Chicken / Egg" question. What comes first, finding all of the right parts to make the plane, and then design the shape of the plane so the parts fit into the plane? Or design the plane and then hunt for parts to fit?
Are y'all actually flying it now, and just releasing video from the can? Mike Patey did that to us on his Scrappy build. :D
How are you powering your avionics? are u using a battery?
Just the tip... That's what she said 😜
When is first takeoff scheduled? Spring?
simple question why no winglet ?
You guys are awesome, love the aircraft. Just surprised to see fuel pumps in the cockpit - any thoughts of an alternate location in the future?
There is another spot we are considering which is the cold side of the firewall forward of the copilot rudder pedals. Still in the cockpit technically but a little more out of the way. We placed the pumps on the side of the fuselage because there was more room there and our original plumbing took up more space than we liked. After we moved to a more compact dual fuel pump manifold it reopened the firewall location as an option.
I wonder how many FEA analysis have you run so far for all the parts for Dark Aero?
She's gonna be a fast one.
If I wear a DarkAero T-shirt, will I look as jacked as Ryley?
You already look jacked. I saw you lifting bags of concrete! A DarkAero shirt would put you at Arnold level.
When you get into production do you expect to convert some of the CNC machined parts to forgings? This will allow for lighter stronger parts. Great video as usual. Keep up the good work.
Hi John! Forged parts would allow for increased optimization on some of the metal components, but the required investment in tooling makes the process a little difficult to adopt for our production volumes. However, we are still looking at converting some more of the metal parts to carbon fiber. A good example of this is the strut bracket we showed at 4:20 in the video.
Never gonna be viable at those volumes I'm afraid
If it's not top secret, can you tell what type of shock absorbers are you using?
Was 4:33 shot late at night? Seems like the word *symmetrical* was being used when *identical* was intended.
Thanks for another interesting video. These are always a lot of fun.
Not shot late at night but agreed that identical would have been a better word choice. Symmetric referred to the part being symmetric about its own mid plane which allows them to be swapped left to right.
@@DarkAeroInc "symmetric about its own mid plane"
Ah, I see now. Thanks for clarifying.
While designing parts, do you follow design standards and procedures, or just wing it and approve the design by doing FEA?
Great question! From a high level, our designs are guided by FAA standards for certified aircraft. We validate our designs through a combination of hand calcs, FEA, and physical testing. Parts made from metal are fairly straightforward to analyze with just hand calcs and FEA. Composite parts are more involved since they are anisotropic so we rely much more on physical testing to validate composite structures. Probably the most extreme example of this is the wing, which we tested in both the positive and negative g directions to confirm it would withstand aerodynamic loads.
@@DarkAeroInc Thanks for the reply. I really do wonder, how is the calc I’m studying in bachelors right now is applied in such a practical manner, where a group of 3 people are doing hand calc at home for making an entire aircraft.
Its composite thats why so many parts
Does static build up on composite airframes the same way as aluminium airframes?
do you have a wag for the kit price?
Do you think you ever offer a larger 4 seat configuration maybe competitive with the RV 10?
A 4-seat version would be a logical progression if we are successful with the 2-seat version of the DarkAero 1. We are hoping to learn as much as possible on this design so we can carry the lessons learned forward into future designs.
Are you still going for split rudder?
Interesting build.....concerning the cam type edge clamps......who makes those? Thank you!
The clamps we used in this video are called Pitbull Clamps and they are made by Mitee-Bite.
@@DarkAeroInc Cool.....thanks again!
I think you would be money ahead and also save time by ordering another vise.
We have been looking at upgrading to a couple Orange or Kurt vises.
I want one. 10/10.
Could I ask you about your wing tip? On modern jets, you see where there is a angled piece to increase the efficiency of the wing through the air and reduce drag. I'm sure you're aware of that but you made the choice to to have a traditional tip. Would you please tell me why, thanks?
Are ya'll planning on doing air-gap seals near the control surfaces?
Yes! Gap seals on all the control surfaces.
@@DarkAeroInc Splendid!
Any possibility of the Rotax 915 (or even the TurbAero turboprop)? Or is the UL520is the only engine?
Great question! Right now the UL520iS is the engine for the DarkAero 1. The airframe is designed and optimized around this powerplant. Everything is pretty tightly coupled so there are a lot of cascading design changes that would be required to adopt more engine options. It’s not something we are completely closed off from but it’s enough work to engineer a solution for one engine already so we are trying to stay focused on getting things right with the UL engine before we increase the scope of the project.
Are you designing for manufacturability as you go? How far from the production design do you think this prototype will be?
Hi Robert! We think a lot about manufacturability as we build the prototype. Even though we call it a prototype, it will be very representative of the production aircraft kits. A big reason we use CNC as much as we do is because it is easily scalable to larger production volumes. We discuss manufacturability a bit in this video. th-cam.com/video/HyOscBDsxjo/w-d-xo.html Thank you for watching!
No winglets? 😎
Engine start soon? 👀
Exactly the plan once we get it up on the landing gear. We are really excited for that day!
Why not have designed the “wing tips” with vortex generators? They are proven to reduce drag, increase lift (about 17% or better) and of negligible use, on such a small aircraft to reduce the spacing of any aircraft behind for turbulence.
It’s your project but I still would have included them for the first two, afore mentioned benefits. I am interested to know if you considered them (vortex generators or wing rakes.)
Best,
G,day River and brothers from Sydney Australia.
Hopefully you are well and enjoying the challenge of manufacture.
Your possibly thinking, get to the point
Your milling and using a router to manufacture the components. Has 3D printing the strength for airplane components?
Be well, take care and have fun
🌏🇦🇺
Hi, I’m just a couch flyer at this point, but I would not use 3D printing for anything structural. I’m sure someone will come along and disagree because it’s the Internet. Also, I’m happy to learn from others.
Hey John! We do have some 3D printed parts in the DarkAero 1, none of them are structural though. Mostly ducts and parts with complicated geometry. We highlighted some of the 3D printing materials and processes we use in this video: th-cam.com/video/F4a-ZQoHnFM/w-d-xo.html
Will dark aero able to land in dirty strips?
Many dirty strips are also short strips, and the DarkAero 1 is not designed to be a STOL airplane. It is primarily intended for paved runways.
What alloy/temper are you using ?
Depends on the part but we use a lot of 6061-T6 and 7075-T6.
Is it physically possible to install that wing-tip upside down?
The tips do not line up correctly if they are swapped left to right or upside down so they only go on one way.
@@DarkAeroInc Good design, but somebody will probably try anyway.
👍👍👍
Just curious if you plan to media blast (shot-pean) and heat treat the machined aluminum landing gear parts for additional strength?
Since planes are expensive (what I call overpriced or opportunity to do better) I suppose even significant reliance on machining might be negligible cost. Do you have a sense of the combined structural cost for the landing gear and is it negligible. And what price segment are you hunching for your go fast 2 seater? Are we talking overpriced LSA at 170-250k? or legacy certified 172 overpriced at 400k. Or newer certified cirrus ridiculous at 800k?
And btw a tube design can of course be trailing arm with shock as well.
All cost info is on their website. www.darkaero.com/aircraft
@@davidowens7040 ah the target price. that's fairly modest by aircraft standards. subject to change :)
That cockpit looks cramped.
Your machining process really scares me! Those parts look very imbalanced and strengthless for the amount of force they are going to handle. Have you heard about symmetrical weight distribution. Parts should be symmetrical to handle all kinds of twists and skewing forces. Your machined parts are very dangerous for human use!
As an aircraft mechanic I can say most look pretty similar to other aircraft parts that aren’t castings or forgings. The stresses are all pretty well known. This isn’t like a dune buggy that’s going to be getting bounced around other than at touchdown. Biggest thing then is side loads if you have a strong crosswind. I would fly in it from what I have seen so far!