Show Notes
Sam Bousfield is the founder and CEO of Samson Sky, a company that is developing the first truly useful flying car. Sam is an architect by training, but a passion for aviation led him to work on a supersonic aircraft with Boeing. Out of this experience came the idea of building a flying car called the Switchblade. Harking from an architectural background, Sam approached the problem of designing a flying car slightly differently. Rather than asking the question of how you could make a car fly, Sam and his team focused on the architectural question of how a vehicle that can both fly and drive should be designed. Answering this question led the Samson team to some unique design choices, such as a three-wheel layout and wings that stow and swing out from underneath the vehicle. One of the other challenges in designing a flying car is striking the right compromise between on-road and off-road performance. For example, a car should preferably create downforce, while a plane should create lift. To achieve this Samson Sky has made some very clever design choices in terms of the layout and shaping of the Switchblade, as well as the positioning of the wings and centre of gravity, and the use of lightweight composite materials. In our conversation, Sam and I talk about: why it has taken so long for a functional flying car to be built the main design challenges that need to be overcome the changes that need to be made to the vehicle when switching between flying and driving the way that Sam envisions the Switchblade to be used in practice and much, much more. If you want to learn more about the topics discussed in this episode, then you can find show notes with links to more in-depth material on the aerospace engineering blog. If you want to support the show then please leave a review; share it on social media with your friends and family; or support the podcast directly on Patreon. Thanks a lot for listening! This episode of the Aerospace Engineering Podcast is brought to you by my patrons on Patreon. Patreon is a way for me to receive regular donations from listeners whenever I release a new episode, and with the help of these generous donors I have been able to pay for much of the expenses, hosting and travels costs that accrue in the production of this podcast. If you would like to support the podcast as a patron, then head over to my Patreon page. There are multiple levels of support, but anything from $1 an episode is highly appreciated. Thank you for your support! This episode is also sponsored by StressEbook.com, which is an online hub for you if you are interested in aerospace stress engineering. StressEbook.com provides world-class engineering services and online courses on the stress analysis of aircraft structures, as well as a free ebook and blog. No matter if you're a junior or senior structural analyst, stressEbook.com provides you with the skills and know-how to become a champion in your workplace.
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Martin Eichenhofer is the CEO & co-founder of 9T Labs, a company that was spun out of ETH Zürich in Switzerland. 9T Labs specialises in providing software solutions and manufacturing equipment for producing high-quality and high-performance composite materials using 3D printing. By marrying the worlds of composite materials and 3D printing, 9T Labs is taking advantage of the superior material properties of composite materials and combining these with the geometric fidelity facilitated by 3D printing. As a result, components that were previously unfeasible to be manufactured using composite materials, either from a technical or cost perspective, are now within the realm of the possible. What is unique about 9T Labs is that the company combines their hardware for 3D printing composite parts with a bespoke optimisation software in order to maximise a component's performance, both in terms of structural design and manufacturing quality. Furthermore, it has been historically difficult to print continuous fibre composites at high quality with a low void content. 9T Labs, however, has patented a process that allows printing at a void content of below 1 percent, which competes with conventionally manufactured composites. So, in this episode of the Aerospace Engineering Podcast, Martin and I discuss: his background as an engineer and how his PhD research led to 9T Labs the challenges and benefits of 3D printing composite materials
Chris Voorhees is the founder and president of First Mode, a Seattle-based company that is designing and building technology for extreme environments off and on planet Earth. Chris has decades of experience in the implementation of robotic systems for the exploration of deep space. His notable experience includes his work as a mobility systems engineer for NASA's Spirit and Opportunity rovers and lead mechanical engineer for NASA's Curiosity rover. For his efforts, Chris received NASA's Exceptional Achievement and Exceptional Engineering Achievement medals. Today, Chris oversees the design, development, and deployment of engineered solutions for missions around the globe and throughout the solar system. First Mode is also focusing on significant problems on Earth including the challenging issues of sustainability for the natural resources sector. In this episode of the Aerospace Engineering Podcast, Chris and I talk about: his background in engineering, including his time at NASA's Jet Propulsion Laboratory his past work on Mars rovers why we should go back to the Moon the space projects First Mode is currently involved with and First Mode’s growing engagement in the hydrogen sector If you want to learn more about the topics discussed in this episode, then you can find show notes with links to more in-depth material on the aerospace engineering blog. If you want to support the show then please leave a review; share it on social media with your friends and family; or support the podcast directly on Patreon. Thanks a lot for listening!
Carl Copeland is the founder of Möbius Aero, an electric air race team, and MμZ Motion, a developer of custom, high-performance electric motors. Carl has built various engineering teams and led innovation in the fields of IT, mechanical, magnetic, and electrical design. He has founded four companies and holds over 25 patents, and his most recent innovation, the Field Modulation Motion System, is a novel electric motor design that is significantly lighter and smaller than established electric motors of similar power and torque ratings. The Field Modulation Motion System achieves its high performance by using 18-phase field modulation rather than the three-phase modulation used in standard motors, essentially emulating six separate three-phase motors attached to a single shaft. Carl is putting his new engine design to the test in a new air racing series for electric aircraft known as Air Race E. In contrast to typical air racing series, in Air Race E aircraft race against each other on a course rather than flying isolated time trials. In the past, air races have been an invaluable means of developing aerospace technology in a competitive setting and Air Race E is re-awakening the spirit of competition by launching the first fully electric airplane race series. In this episode of the Aerospace Engineering Podcast, Carl and I talk about: his unique and auto-didactic background in engineering his goal of finding practical solutions to humanity's problems the Air Race E competition and the origin story of Carl’s racing team Möbius Aero the technical details and benefits of his new electric motor and the impact this has on airframe development If you want to learn more about the topics discussed in this episode, then you can find show notes with links to more in-depth material on the aerospace engineering blog. If you want to support the show then please leave a review; share it on social media with your friends and family; or support the podcast directly on Patreon. Thanks a lot for listening!
Dr Evangelos Zympeloudis is the CEO and co-founder of iCOMAT, a company based in the UK that is developing automated manufacturing equipment for tow-steered composite materials. Fibre-reinforced plastics, such as carbon-fibre or glass-fibre composites, hold great promise for high-performance and lightweight design due to their excellent stiffness and strength properties at low material density. Traditional fibre-reinforced plastics are manufactured using straight uni-directional fibres or with straight fibres woven into a fabric. Generally speaking, a fibre-reinforced composite derives its strength by aligning the fibres with the direction of the dominant load path. The novelty of tow-steered composites is that strips of composite material, so-called fibre tows, are steered along curvilinear paths such that the fibre direction is not straight, but varies continuously from point to point. This characteristic has benefits in structural design as the reinforcing fibres can now be used to smoothly tailor stiffness and strength throughout the structure. For example, tow-steered composites can be used to curve the reinforcing fibres around windows in an aircraft fuselage in order to improve strength and facilitate net-shape manufacturing. In this episode of the Aerospace Engineering Podcast, Evangelos and I talk about: his background as an engineer and entrepreneur the manufacturing challenge of making defect-free tow-steered composites the capabilities of iCOMAT’s rapid tow-shearing process the benefits of tow-steering for manufacturing cost and design and some of the projects iCOMAT is currently working on If you want to learn more about the topics discussed in this episode, then you can find show notes with links to more in-depth material on the aerospace engineering blog. If you want to support the show then please leave a review; share it on social media with your friends and family; or support the podcast directly on Patreon. Thanks a lot for listening! Disclosure: I currently work with iCOMAT on a number of projects and am a consultant to the company.
Stefan Brieschenk is the Chief Operating Officer of Rocket Factory Augsburg (RFA), a company in the south of Germany that is developing a low-cost launch vehicle. RFA’s vision is to drastically reduce the cost of access to space through large-scale industrialisation of their operations and manufacturing. Key to RFA's design approach is a holistic performance and cost optimisation tool that has been developed in collaboration with space industry veterans MT Aerospace and OHB. This approach has led to interesting design choices. For example, the second stage tank is based on inexpensive stainless steel construction, and in places where composite materials are being used, RFA is relying on automotive grade materials that have already been used in high-volume production. In their propulsive system, however, RFA is chasing the highest performance—a closed-cycle staged combustion engine, enabled by modern manufacturing capabilities in 3D printing and which is due to be hot-fired early next year. In this episode of the Aerospace Engineering podcast, Stefan and I talk about: Stefan’s passion for rocketry and hypersonic flight his background at Rocket Lab and MT Aerospace the gap between the European and US space sectors RFA’s launch vehicle and design approach and Stefan’s vision for the European space sector If you want to learn more about the topics discussed in this episode, then you can find show notes with links to more in-depth material on the aerospace engineering blog. If you want to support the show then please leave a review; share it on social media with your friends and family; or support the podcast directly on Patreon. Thanks a lot for listening!