Introduction: The Dawn of Hybrid Transportation
Imagine driving a vehicle through city streets and then effortlessly transitioning into flight. The concept of roadable aircraft—vehicles that seamlessly operate on roads and in the skies—has evolved from a futuristic vision into a tangible reality. A Massachusetts-based startup aimed to pioneer this hybrid transportation revolution by developing a chassis system capable of performing in both automotive and aerospace environments. This ambitious project demanded a rare combination of automotive precision, aviation safety compliance, lightweight material engineering, and aerodynamic optimization.
Goken, a leader in advanced mobility solutions, partnered with the startup to bring this vision to life. Leveraging expertise in structural design, regulatory compliance, and aerospace engineering, Goken delivered a groundbreaking, regulation-compliant roadable aircraft chassis system—an engineering milestone that sets a new industry standard.
The Challenge: Engineering for Dual Environments
Developing a chassis system for a roadable aircraft required more than adapting an existing vehicle design. The system needed to meet stringent dual-mode requirements: compliance with Federal Motor Vehicle Safety Standards (FMVSS) for road use and FAA/ASTM standards for Light Sport Aircraft in flight. Additionally, the chassis had to balance lightweight construction with structural integrity while ensuring reliability and durability across diverse operating conditions.
The project faced several critical hurdles:
- Software Compatibility: The client relied exclusively on SOLIDWORKS for CAD and CAE, necessitating seamless integration with Goken’s workflows.
- Accelerated Timelines: Tight schedules required Informal Peer Reviews (IPR) and Preliminary Design Reviews (PDR) within two months.
- Chassis Development Expertise Gap: The client lacked prior experience in chassis engineering and had no established validation plans.
- Limited Testing Resources: Budget constraints restricted access to advanced testing facilities.
- Material Challenges: The use of carbon fiber, titanium, stainless steel, and aluminum introduced risks of galvanic corrosion at critical joints.
The Solution: Goken’s High-Impact Engineering Approach
Goken tackled these challenges with a strategic, multidisciplinary approach, emphasizing precision engineering, lightweight structural design, and regulatory compliance.
Precision Engineering for a Dual-Mode Chassis
- Kinematic Analysis: Goken conducted dynamic simulations to optimize chassis behavior for both driving and flight, ensuring aerodynamic efficiency, stability, and weight balance.
- Advanced CAE Modeling: Structural Finite Element Analysis (FEA), Computational Fluid Dynamics (CFD), and load distribution simulations refined material selection and weight distribution.
- Material Strategy: A balance of lightweight construction, crashworthiness, and fatigue resistance was achieved while addressing galvanic corrosion and mechanical wear.
Fast-Track Development Strategy
- Extended Engineering Cycles: Goken’s team worked tirelessly to meet FAA and FMVSS review deadlines across multiple design iterations.
- Custom Validation Protocols: Bespoke testing plans were developed, including vibration testing, thermal expansion modeling, and stress-strain analysis.
- Cost-Effective Testing: Simulation-driven validation, prototype optimization, and real-world load testing minimized reliance on expensive facilities.
Corrosion Prevention and Structural Reinforcement
- Protective Measures: Aerospace-grade coatings, anodization, and anti-corrosion treatments were applied to mitigate material degradation.
- Joint Optimization: Fastener placement and stress distribution modeling enhanced durability, reduced mechanical stress, and prevented corrosion-related failures.
The Results: Transforming Roadable Aircraft Development
Goken’s collaboration with the startup yielded exceptional outcomes:
- On-Time Delivery: All project milestones, including IPR, PDR, and structural validation tests, were completed on schedule.
- Comprehensive Documentation: Goken provided system FMEA, CAD models, crash simulation reports, and scalable design frameworks.
- Performance Optimization: Improved aerodynamics, lift-to-drag ratio, and structural rigidity were achieved while reducing manufacturing costs.
- Cost Savings: By leveraging Ohio-based aerospace engineering resources, Goken avoided reliance on high-cost markets.
- Regulatory Compliance: The chassis met FMVSS, FAA Part 23, ASTM F2245, and Light Sport Aircraft certification standards, ensuring market readiness.
Conclusion: Pioneering the Future of Mobility
Goken’s work on this roadable aircraft chassis system exemplifies the power of innovative engineering to bridge automotive and aerospace domains. This breakthrough not only validates the feasibility of hybrid transportation but also lays the groundwork for advancements in urban air mobility (UAM), electric vertical takeoff and landing (eVTOL) vehicles, and AI-driven navigation technologies. As the global transportation landscape evolves, Goken remains committed to transforming visionary ideas into reality.
For organizations seeking to lead the next wave of mobility innovation, Goken offers unmatched expertise and a proven track record. Contact us to explore how we can accelerate your journey into the future of transportation.
