MAST Plane Design

Challenge:
Every year, the McMaster Aerospace Team (MAST) designs and builds a new plane to compete in the SAE Aero Design East Competition, bringing together universities from around the world. Teams are tasked with designing and constructing a 15-foot unmanned, fixed-wing aircraft capable of completing a specific challenge. For the two years I’ve participated, the challenge was to build a plane that could carry as much payload weight as possible while taking off from a 100-foot runway.

Experience: 

Year 1: Fuselage Subteam Member

Our competitive season is divided into two key phases: design and build. As a member of the fuselage subteam, my initial role involved collaborating with teammates to define critical parameters, such as dimensions, connection points, and payload entry/exit mechanisms. With these fundamentals established, each subteam member focused on individual tasks. My responsibilities included:

• Weight Optimization: Integrating weight-relieving structures into the fuselage design using CAD software.

• Wing Integration: Designing mounting points and a resting spot tailored to our wing profile.

• Assembly Management: Acting as the editor of our fuselage assembly file, troubleshooting and repairing broken relationships in the CAD model.

During the build phase, I developed and employed precision jigs, optimized manufacturing processes for dimensional accuracy, and tackled unexpected challenges with on-the-fly solutions. At the competition in Lakeland, Florida, I assembled the plane daily to prepare it for flight and repaired any damage, as needed.

Year 2: Payload and Landing Gear Subteam Lead 

In my second year, I was selected to lead the payload and landing gear subteam. This role encompasses overseeing the construction of:

• Landing Gear: Ensuring it effectively protected the aircraft from damage during landing.

• Payload System: Designing a payload mechanism for efficient loading and unloading, with quick and painless weight adjustments.

I also mentor and delegate tasks to three teammates, fostering collaboration and learning. Key contributions so far include:

• Identifying and Resolving Design Flaws: Addressed a critical issue from the previous year’s competition that prevented successful takeoff, devising a new wheel and axle system to reduce rolling resistance and enhance runway speed.

• Simulation and Testing: Created MATLAB programs to simulate ground impact forces, landing gear deformation, optimal wheel size, and payload placement. These tools minimized the time and costs associated with testing inefficient designs.

• Innovative Testing Setup: Designed and built a rolling resistance test using spare RC parts and a 3D-printed stand (modeled in SolidWorks). This provided valuable data for the wings and tail subteams to accurately simulate takeoff performance.

This project is allowing me to refine my technical, leadership, and problem-solving skills while contributing to innovative aerospace solutions. The challenges and successes of each season strengthen my passion for engineering and my commitment to advancing in the aerospace field.

Tools & Technologies: 

• Software: SolidWorks, MATLAB, Microsoft Teams, PowerPoint, Word.

• Equipment: 3D printers, lathe, bandsaw, laser cutter, powered hand drills, screwdrivers, files.