Installation of mechanical mounting brackets

The empennage of AeroMobil 4.0 prototype flight vehicle is fitted with metal brackets for the flight control system and rear suspension. Each bracket has been precision machined and positioned using the latest 3D measurement techniques. Installation of the brackets will allow closure of empennage assembly and progression to the next stage, the installation of the required control surfaces.

Installation of mechanical mounting brackets
Empennage Assembly progresses to next stage of manufacturing

Empennage Assembly progresses to next stage of manufacturing

The AeroMobil team have now removed three main support tools from the composite empennage assembly. The next stage is installation of metal brackets. These small, but important components will connect the mechanical parts of the rear suspension and flight control system. In parallel, wings manufacturing activities are progressing in line with our plans.

Preparing for Wing Manufacture

Start of manufacture of the wings for AeroMobil 4.0 is another important milestone for the programme. The wing structure, geometry and aerodynamic shape are specifically designed to provide lift for this innovative vehicle, very important in ensuring confident handling and high manoeuvrability. The wing design for AeroMobil 4.0 has to take account of the requirement for transformation of the vehicle from a plane to a car and have therefore also been optimised to stow neatly and safely along the fuselage. During the upcoming weeks these tools will be used to manufacture the wing outer surfaces and also create the final assembly of the AeroMobil 4.0 prototype wings.

Preparing for Wing Manufacture
Completion of lower part of empennage

Completion of lower part of empennage

AeroMobil workshop intensity increases. The empennage is being assembled in the inverted position and in this stage the bottom panels are lowered into position, together with mould, to enable bonding to be completed. This stage of process brings together the main sections of the bonding jig that will enable the finalisation of the assembly and can be seen in our video at stage 7.

Bonding of structural parts

Our test vehicle carbon fibre empennage build progresses according to the plan. Empennage assembly started with bonding of  the internal components that  are crucial for the structural strength of the unit. Each component is accurately positioned according to the detailed assembly drawings thus ensuring they provide the required stiffness in the assembly.  The empennage supports the propeller and shaft, rear suspension units and flying control systems for the lightweight bonded carbon fibre elevator and rudder assemblies that will be added at a later date. 

Bonding of structural parts

Designing our vehicles

AeroMobil uses Dassault Systèmes’ 3DEXPERIENCE platform not only to manage the lifecycle of its vehicle and to help ensure regulatory compliance but also to find the best design before physical prototyping. Find out more in the case study video created in partnership with Dassualt Systèmes.

Prototype test vehicle frame is installed and ready for the build

The AeroMobil 4.0 test vehicle frame has been delivered on plan and is first in the jig at the vehicle assembly station. This important component was delivered to our hangar and has undergone rigorous quality checks. We have designed a traditional steel frame fuselage structure, keeping costs low while allowing ease of adjustment during assembly and testing. The full carbon fuselage will be introduced later in the test programme once system performance has been optimised. Follow the vehicle assembly over the coming weeks!

Prototype test vehicle frame is installed and ready for the build

Empennage build video

One of the most advanced parts of our new experimental test vehicle is the empennage, which is also known as the tail or tail assembly. This structure will provide AeroMobil stability during flight. The empennage is a lightweight bonded assembly with a retractable rear bumper. The carbon monocoque empennage supports the propeller and shaft, rear suspension units and flying controls. The unit also houses lightweight bonded carbon elevator and rudder assemblies balanced for free operation.

Assembly assesment

Empennage panels are stacked for a preliminary assembly assessment, and they matched perfectly. Achieving high levels of manufacturing quality is our key priority for this key structural assembly.

Assembly assesment
Panels removed from the tools

Panels removed from the tools

Carbon fibre panel after removal from the tool. Every element of the panel and its production record is checked to ensure that it is manufactured according to the highest standards and meets the required engineering and quality parameters.

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