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

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!

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

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.

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.

Panels removed from the tools
Bigger panels ready

Bigger panels ready

Some of the bigger panels that form the major sections of the empennage are complex. Following careful removal from the tools and trimming they are thoroughly checked to ensure they meet the engineering specification.

Preparation for trimming

Cured parts are removed from the moulds and trimmed according to engineering trimming instructions.

Preparation for trimming
First parts manufactured

First parts manufactured

With tooling preparation completed on the moulds in our facility, we started to manufacture the first parts. Carbon fibre plies and required filler materials are cut, layered and impregnated with resin according to the engineering instructions.

New prototype under development

The work on our next physical experimental prototype begins! First composite manufacturing moulds for our new flight test vehicle were delivered to our facility. Strict engineering procedures and plans for manufacturing are developed to ensure control during the production process.

The composite moulds are digitally scanned to confirm the tool surface and dimensions match the engineering design before they are used.

New prototype under development

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