Using a CNC Router to Machine Aerospace Mold Patterns (part 1) DarkAero, Inc 2020-07-13 | DarkAero Mold Making Course Now Available - darkaero.com/courses/mold-makingJoin the DarkAero Community - youtube.com/darkaeroinc/join(Exclusive members only content including photos, videos, live Q&A and more!)Part 2: youtu.be/7_D7Jav0_ooDarkAero 1 - darkaero.com/aircraftDarkAero Apparel - darkaero.com/shopIn this video we cover why we selected an AVID CNC router to machine out all the mold patterns for the DarkAero 1 experimental kit aircraft.Our top reasons for choosing this CNC router over others included:1. The Avid CNC router fit the right overlap for cost, machine volume, and accuracy/precision.2. The parts for the CNC router are easy to replace. 3. The CNC router is really easy to setup and quickly learn on compared to larger, industrial grade routers. 4. The CNC router is low power and great for smaller size shops.5. It is big enough to get larger jobs done but not so big that it will occupy a large amount of shop space. 6. It is versatile in the sense that it can be used to machine out large parts like mold patterns and smaller parts like carbon fiber brackets.Some of the machine's "upgrades" include:1. Going with an HDPE "spoilboard"2. Increasing the number of cross braces for the machine3. Developing an ongoing leveling procedure 4. Opting for the lower Z height travel to reduce relative gantry motion when cuttingStay tuned for part 2 where we go into more details on how we use this CNC router to machine out multi section mold patterns for creating carbon fiber parts. If you enjoyed this video and would like to see more of this type of content, follow along as we work to create the fastest, longest range aircraft you can build in your garage. More information on DarkAero can be found on our website and other social media accounts: darkaero.comfacebook.com/darkaeroincinstagram.com/darkaeroinclinkedin.com/company/darkaero-inc
How this machine transformed our capability overnight DarkAero, Inc 2024-04-24 | Recently, we parted ways with our Tormach PCNC 1100 and progressed to a completely new machine that will dramatically increase our CNC machining capability: the new Tormach 1500MX. This video gets into the details behind this machine, how it's already helping us make parts for the DarkAero 1 prototype, and how it will carry us into making production parts for kits. DarkAero Careers - darkaero.com/careersDarkAero 1 Aircraft - darkaero.com/aircraftDarkAero Courses - darkaero.com/coursesDarkAero Services - darkaero.com/servicesDarkAero Apparel - darkaero.com/shopIf you enjoyed this video and would like to see more of this type of content, follow along as we work to engineer the fastest, longest-range aircraft you can build in your garage!0:00 - Intro1:00 - DarkAero 1 Prototype1:53 - 1500MX Specs, Features3:55 - Machining Demo7:16 - The Key Advantage of this Machine9:58 - Final ThoughtsMore information on DarkAero can be found on our website and other social media accounts: darkaero.cominstagram.com/darkaeroinclinkedin.com/company/darkaero-inctwitter.com/DarkAeroInc
Ground Testing the DarkAero 1 DarkAero, Inc 2024-02-20 | Check out darkaero.com/careers to join our team! In today's video, we go over the ground testing that is being done to prep the DarkAero 1 for upcoming flight tests as well as the work that's being wrapped up in the cabin.DarkAero 1 Aircraft - darkaero.com/aircraftDarkAero Courses - darkaero.com/coursesDarkAero Services - darkaero.com/servicesDarkAero Apparel - darkaero.com/shopIf you enjoyed this video and would like to see more of this type of content, follow along as we work to engineer the fastest, longest-range aircraft you can build in your garage!0:00 - Intro0:19 - Testing the Wing Tanks3:20 - Load Testing the Control Surfaces6:13 - Seat Belt Installation8:06 - AnnouncementMore information on DarkAero can be found on our website and other social media accounts: darkaero.cominstagram.com/darkaeroinclinkedin.com/company/darkaero-inchttps://x.com/DarkAeroInc
The biggest myth about split flaps DarkAero, Inc 2023-12-22 | Check out Xometry at xometry.com/darkaeroIn this video, we dive into the details behind the decision to use a split flap design over other common options like the plain flap and how the mechanism for the flap system on the DarkAero 1 works. We also address some misconceptions that surround split flap designs, specifically around the drag they produce when deployed. Additional resources on the lift and drag characteristics of split flaps vs plain flaps:NACA Report No. 661: ntrs.nasa.gov/api/citations/19930091736/downloads/19930091736.pdfNACA Report No. 554: ntrs.nasa.gov/api/citations/19930091629/downloads/19930091629.pdfNACA BOUNDARY—LAYER AND STALLING CHARACTERISTICS OF TWO SYMMETRICALNACA LOW—DRAG AIRFOIL SECTIONS: ntrs.nasa.gov/api/citations/19930093812/downloads/19930093812.pdfDarkAero 1 Aircraft - darkaero.com/aircraftDarkAero Courses - darkaero.com/coursesDarkAero Services - darkaero.com/servicesDarkAero Apparel - darkaero.com/shopIf you enjoyed this video and would like to see more of this type of content, follow along as we work to engineer the fastest, longest-range aircraft you can build in your garage!0:00 - Intro1:34 - Flap Design Options7:50 - Which has more Drag?10:08 - How our flaps work13:01 - What's Next?More information on DarkAero can be found on our website and other social media accounts: darkaero.cominstagram.com/darkaeroinclinkedin.com/company/darkaero-inchttps://x.com/DarkAeroInc
What makes our flight controls different DarkAero, Inc 2023-10-05 | Try Onshape for free! https://onshape.pro/darkaeroIn this video, we dive into the flight controls for the DarkAero 1 and some of the recent work we’ve been doing to refine the control system before flight testing. We discuss the split rudder design, how we packaged the controls into a small airframe, and the interesting material we used to counterbalance the ailerons and elevators.DarkAero Courses: darkaero.com/courses0:00 - Intro1:05 - Controls Walkthrough4:44 - Controls CAD8:31 - Controls Requirements11:39 - What's Next?Also check out:DarkAero 1 Aircraft - darkaero.com/aircraftDarkAero Services - darkaero.com/servicesDarkAero Apparel - darkaero.com/shopMore information on DarkAero can be found on our website and other social media accounts: darkaero.cominstagram.com/darkaeroinclinkedin.com/company/darkaero-inctwitter.com/DarkAeroInc
Puller vs Pusher Aircraft - Which is More Efficient? DarkAero, Inc 2023-09-22 | Check out Xometry at xometry.com/darkaeroThe DarkAero 1 is engineered to fly fast while maintaining high efficiency, and we located the propeller at the front of the airplane even though it has long been theorized that placing the prop at the back so it pushes would be better for speed and efficiency. So why is our propeller at the front? Would the DarkAero 1 actually be better with the prop in back?DarkAero 1 Aircraft - darkaero.com/aircraftDarkAero Courses - darkaero.com/coursesDarkAero Services - darkaero.com/servicesDarkAero Apparel - darkaero.com/shopIf you enjoyed this video and would like to see more of this type of content, follow along as we work to create the fastest, longest-range aircraft you can build in your garage!More information on DarkAero can be found on our website and other social media accounts: darkaero.cominstagram.com/darkaeroinclinkedin.com/company/darkaero-inctwitter.com/DarkAeroInc
The Truth About Carbon Fiber: Myths vs. Reality DarkAero, Inc 2023-08-25 | Learn more about DarkAero Courses here: darkaero.com/coursesThis video is about carbon fiber and some of the myths surrounding this material. We used carbon fiber extensively in the DarkAero 1, and its material properties are part of what allows us to achieve our design goals for the aircraft. Carbon fiber can be complicated to design and work with, so it’s understandable that there are some misconceptions surrounding this material. Let's dive deeper into these myths and gain a better understanding of carbon fiber.0:00 - Intro0:31 - Myth 1: All Carbon Fiber is the Same3:38 - Myth 2: Carbon Fiber Compression Strength5:17 - Myth 3: Carbon Fiber Fatigue Strength9:27 - SummaryDarkAero Courses - darkaero.com/coursesDarkAero 1 Aircraft - darkaero.com/aircraftDarkAero Services - darkaero.com/servicesDarkAero Apparel - darkaero.com/shopIf you enjoyed this video and would like to see more of this type of content, follow along as we work to engineer the fastest, longest-range aircraft you can build in your garage!More information on DarkAero can be found on our website and other social media accounts: darkaero.cominstagram.com/darkaeroinclinkedin.com/company/darkaero-inchttps://x.com/DarkAeroIncSources used in this video: Toray TORAYCA™ carbon fiber: toraycma.com/products/carbon-fiberCompressive and Tensile Strength Values for Carbon Fiber: https://agate.niar.wichita.edu/Compressive Strength of Grade 5 Titanium: asm.matweb.com/search/SpecificMaterial.asp?bassnum=mtp641Fatigue of Composites by Michael J. Salkind: ntrs.nasa.gov/api/citations/19720022254/downloads/19720022254.pdfAirbus Aircraft "Save up to 25% maintenance costs with the A350": aircraft.airbus.com/en/save-up-to-25-maintenance-costs-with-the-a350
What happens when a design fails? DarkAero, Inc 2023-08-02 | Try Onshape for free! https://onshape.pro/darkaeroThe DarkAero 1 fuel sump was recently tested, and it did not perform as expected. The testing revealed a leak, which led to a redesign of the sump to fix the leak but also improve it overall. Let's take a look at the engineering process of redesigning this key piece of hardware. If you've wanted to learn how to create your own molds and high quality composite parts, check out: darkaero.com/coursesAlso check out:DarkAero 1 Aircraft - darkaero.com/aircraftDarkAero Services - darkaero.com/servicesDarkAero Apparel - darkaero.com/shopIf you enjoyed this video and would like to see more of this type of content, follow along as we work to engineer the fastest, longest-range aircraft you can build in your garage!More information on DarkAero can be found on our website and other social media accounts: darkaero.cominstagram.com/darkaeroinclinkedin.com/company/darkaero-inctwitter.com/DarkAeroInc
Big Engine, Small Airframe: Did we reach the limit? DarkAero, Inc 2023-07-01 | Learn how to make your own high-quality carbon fiber parts: darkaero.com/coursesJoin the DarkAero Community! youtube.com/darkaeroinc/join(Exclusive, members only content including photos, videos, live Q&A and more!) In this video we discuss the challenges of installing the UL Power UL520iS engine in the DarkAero 1. Specifically, the packaging problem of fitting a six cylinder engine into the aircraft while still providing forward baggage space. DarkAero 1 Aircraft - darkaero.com/aircraftDarkAero Services - darkaero.com/servicesDarkAero Apparel - darkaero.com/shopIf you enjoyed this video and would like to see more of this type of content, follow along as we work to engineer the fastest, longest-range aircraft you can build in your garage!More information on DarkAero can be found on our website and other social media accounts: Website: darkaero.comInstagram: instagram.com/darkaeroincLinkedIn: linkedin.com/company/darkaero-incTwitter: twitter.com/DarkAeroInc
Designing smarter landing gear DarkAero, Inc 2023-06-01 | Move your project from concept to completion faster through our engineering services: darkaero.com/servicesIn this video, we explain how we made the DarkAero 1 landing gear smarter through the addition of logic control and how we built our system to simplify the challenge of actuating all three gear struts. Join the DarkAero Community! youtube.com/darkaeroinc/join(Exclusive, members only content including photos, videos, live Q&A and more!) DarkAero Courses - darkaero.com/coursesDarkAero 1 Aircraft - darkaero.com/aircraftDarkAero Services - darkaero.com/servicesDarkAero Apparel - darkaero.com/shop0:00 - Intro0:52 - Retract Requirements1:39 - The Path to Smarter Gear3:37 - Let's Move the Gear!5:59 - Electric vs Hydraulic7:16 - What's Next? If you enjoyed this video and would like to see more of this type of content, follow along as we work to engineer the fastest, longest-range aircraft you can build in your garage!More information on DarkAero can be found on our website and other social media accounts: darkaero.cominstagram.com/darkaeroinclinkedin.com/company/darkaero-inc
We have all three landing gear struts operating together now! New video coming soon! DarkAero, Inc 2023-05-27 | ...
Rotating the DarkAero 1 fuselage DarkAero, Inc 2023-05-26 | Sometimes it’s useful to reorient things for better access or better ergonomics during the assembly of a kitplane. The lighter the construction, the easier it is to move, so keeping things light means easier to build!The fuselage of the DarkAero 1 is light enough that two people can roll it inverted during construction without much difficulty. An example of this operation can be seen here as we repositioned the fuselage this morning for improved access while installing the antennas and seatbelt hard points.
Engineering softer landings (drop testing) DarkAero, Inc 2023-04-29 | Thank you to Onshape for sponsoring this video!Get started with Onshape today: https://Onshape.pro/DarkAeroIn this video we'll be drop testing the nose gear of the DarkAero 1 prototype. The goal is to simulate a bad landing in a safe and controlled manner so that we can verify that the nose gear will perform as expected before we proceed into flight testing. Before we drop the nose gear to see how it performs, we'll take a closer look at the gear design, the test rig, and discuss the importance of this test.0:00 - Intro0:40 - DarkAero 1's Mission1:56 - Nose Gear Engineering4:46 - Why Drop Test The Gear? 6:20 - Test Setup8:07 - Testing Results10:00 - OutroJoin the DarkAero Community! youtube.com/darkaeroinc/join(Exclusive, members only content including photos, videos, live Q&A and more!) DarkAero 1 Aircraft - darkaero.com/aircraftDarkAero Courses - darkaero.com/coursesDarkAero Services - darkaero.com/servicesDarkAero Apparel - darkaero.com/shopIf you enjoyed this video and would like to see more of this type of content, follow along as we work to create the fastest, longest-range aircraft you can build in your garage!More information on DarkAero can be found on our website and other social media accounts: darkaero.cominstagram.com/darkaeroinclinkedin.com/company/darkaero-inc
The engineering challenge of electrifying airplanes DarkAero, Inc 2023-04-17 | Learn how to make your own high-quality carbon fiber parts: darkaero.com/coursesThroughout the development of the DarkAero 1, we've often been asked, "Will you make an electric version of the aircraft?" In this video we explore the underlying physics that govern this problem and look at what it would take to go electric. 0:00 - Intro0:34 - Gravimetric Energy Density3:54 - Electric Motors4:59 - Hydrogen? 5:38 - Where Electric Works6:46 - Why Weight Matters8:00 - Final ThoughtsDarkAero Courses - darkaero.com/coursesDarkAero 1 Aircraft - darkaero.com/aircraftDarkAero Knowledge Base - darkaero.com/knowledgeDarkAero Apparel - darkaero.com/shopIf you enjoyed this video and would like to see more of this type of content, follow along as we work to create the fastest, longest-range aircraft you can build in your garage!More information on DarkAero can be found on our website and other social media accounts: darkaero.cominstagram.com/darkaeroinclinkedin.com/company/darkaero-incSources used in this video:Amprius 500 Wh/kg Battery: amprius.com/the-all-new-amprius-500-wh-kg-battery-platform-is-hereTesla 4680 Specs: insideevs.com/news/598656/tesla-4680-battery-cell-specsEnergy Density of Gasoline: energyeducation.ca/encyclopedia/Energy_densityUL Power 520iS Specs: ulpower.com/en/engines/ul520/ul520is#4-fuelWeight of Gasoline: jdpower.com/cars/shopping-guides/how-much-does-gasoline-weigh-per-gallon#:~:text=How%20Much%20Does%20A%20Gallon,%2C%20gasoline%20is%2025%25%20lighter.H3X HPDM-250 Electric Motor: https://www.h3x.tech/#hdpm-250 Energy Density of Hydrogen: energy.gov/eere/fuelcells/hydrogen-storage#:~:text=On%20a%20volume%20basis%2C%20however,based%20on%20lower%20heating%20values.Eviation Alice: eviation.comBeta Technologies: https://www.beta.team/aircraft/Tesla Investor Day 2023: youtube.com/live/Hl1zEzVUV7w?feature=shareVideo Sources: "The Story of Solar Impulse: Exploration to Change to World": youtu.be/QS4ira-1AL0"Pipistrel Velis Electro | the world's first type-certified electric aeroplane": youtube.com/watch?v=GC7ydEpVNfA&t=19s"eXenos Electric Motorglider": youtube.com/watch?v=mLSb6z_tKj4&t=68s"ALIA Highlight Reel 2022": youtube.com/watch?v=kH4LKlfdkiw"First Flight of Eviation's All-Electric Alice Aircraft": youtube.com/watch?v=RnA5HXerVa0
Why we designed our own retractable landing gear DarkAero, Inc 2023-03-25 | Learn how to make your own high-quality carbon fiber parts: darkaero.com/coursesDarkAero 1 Aircraft - darkaero.com/aircraftDarkAero Knowledge Base - darkaero.com/knowledgeDarkAero Apparel - darkaero.com/shopJoin the DarkAero Community - youtube.com/darkaeroinc/join(Exclusive members only content including photos, videos, live Q&A and more!) 0:00 - Intro1:49 - Main Gear Overview4:04 - Gearbox Design4:51 - Emergency Extension 6:00 - Gearbox Fabrication7:12 - Why build our own?7:57 - Next StepsIn this video, we discuss one of the major tasks we've been focused on lately leading up to flight testing, which is our retract system for the main landing gear. If you enjoyed this video and would like to see more of this type of content, follow along as we work to create the fastest, longest-range aircraft you can build in your garage!More information on DarkAero can be found on our website and other social media accounts: darkaero.cominstagram.com/darkaeroinclinkedin.com/company/darkaero-inc
New Torque Links for Nose Landing Gear: Exciting Upgrades Coming Soon! DarkAero, Inc 2023-03-08 | We’ve been working in the background on a few modifications to some landing gear parts. These are the new torque links for the nose landing gear. They interface with a few new parts that we are excited to share more about very soon!
“Don’t paint it!” …(we painted it) DarkAero, Inc 2023-02-01 | Learn how to make your own high-quality carbon fiber parts: darkaero.com/coursesWe recently finished up applying primer to the airframe of the DarkAero 1. We had the airplane disassembled for that project but now we are in the process of putting everything back together. We thought it would be a good time to pause and show you the results of the paint work since the airplane obviously looks pretty different compared to its original naked carbon look. We also wanted to discuss some more of the details and lessons learned from painting and talk through what is next before we fly the airplane.DarkAero 1 Aircraft - darkaero.com/aircraftDarkAero Knowledge Base - darkaero.com/knowledgeDarkAero Apparel - darkaero.com/shopIf you enjoyed this video and would like to see more of this type of content, follow along as we work to create the fastest, longest-range aircraft you can build in your garage!More information on DarkAero can be found on our website and other social media accounts: darkaero.cominstagram.com/darkaeroinclinkedin.com/company/darkaero-incNikafshar S, Zabihi O, Ahmadi M, Mirmohseni A, Taseidifar M, Naebe M. The Effects of UV Light on the Chemical and Mechanical Properties of a Transparent Epoxy-Diamine System in the Presence of an Organic UV Absorber. Materials (Basel). 2017 Feb 14;10(2):180. doi: 10.3390/ma10020180. PMID: 28772538; PMCID: PMC5459211.
Carbon fibers are smaller than you think DarkAero, Inc 2023-01-13 | Follow along with us to learn more about aerospace composites and carbon fiber!
How to make ‘forged’ carbon fiber parts DarkAero, Inc 2023-01-08 | To learn more about how to make ‘forged’ carbon and other carbon fiber parts, check out our Aerospace Composites Course at darkaero.com/courses
Engineering the fastest, longest-range aircraft you can build in your garage DarkAero, Inc 2022-12-29 | Learn how to make your own high-quality carbon fiber parts: darkaero.com/courses2022 was a significant year for DarkAero, both in terms of progress on the DarkAero 1 and growth of DarkAero as a company. Important milestones were achieved that brought the DarkAero 1 prototype closer to first flight, a new facility was secured for initial production of DarkAero 1 kits, and the offering of DarkAero courses grew. Thank you all for your support! We can't wait to share more in 2023! DarkAero Courses - darkaero.com/coursesDarkAero 1 Aircraft - darkaero.com/aircraftDarkAero Knowledge Base - darkaero.com/knowledgeDarkAero Apparel - darkaero.com/shopJoin the DarkAero Community! youtube.com/darkaeroinc/join(Exclusive, members only content including photos, videos, live Q&A and more!) If you enjoyed this video and would like to see more of this type of content, follow along as we work to engineer the fastest, longest-range aircraft you can build in your garage!More information on DarkAero can be found on our website and other social media accounts: darkaero.cominstagram.com/darkaeroinclinkedin.com/company/darkaero-inc
How to make lighter carbon fiber parts DarkAero, Inc 2022-12-20 | Wet layup is a quick and easy way to make a composite part. However, by compressing a part made using wet layup under vacuum and drawing the excess resin into a consumable layer, you can dramatically decrease the final part weight while maintaining its strength.
The next frontier in aviation... DarkAero, Inc 2022-12-16 | Try Onshape for free: https://Onshape.pro/DarkAeroDarkAero Courses - darkaero.com/coursesDarkAero 1 Aircraft - darkaero.com/aircraftDarkAero Knowledge Base - darkaero.com/knowledgeDarkAero Apparel - darkaero.com/shopJoin the DarkAero Community - youtube.com/darkaeroinc/join(Exclusive members only content including photos, videos, live Q&A and more!) 00:00 - Design for Manufacturing1:21 - Onshape CAD Model2:58 - Mold Patterns4:37 - Molds8:43 - Infusion Process9:25 - Automation10:30 - Assembly11:21 - Post Curing13:09 - Why Manufacturing MattersIn this video, we show how we built the carbon fiber wing for the DarkAero 1, but more importantly discuss one of the most overlooked aspects of composites, which is mass production. Why is it so hard to manufacture composite structures? Is automation possible? What are some of the secrets we figured out to tackle manufacturing for the DarkAero 1?If you enjoyed this video and would like to see more of this type of content, follow along as we work to create the fastest, longest-range aircraft you can build in your garage!More information on DarkAero can be found on our website and other social media accounts: darkaero.comfacebook.com/darkaeroincinstagram.com/darkaeroinclinkedin.com/company/darkaero-inc
Create 3D parts from a flat mold? DarkAero, Inc 2022-12-11 | Is it possible to create 3D carbon fiber parts using only a flat plate mold?
Don’t make this part out of carbon fiber. DarkAero, Inc 2022-12-08 | Subscribe if you'd like to learn more about these types of design challenges on our aircraft, the DarkAero 1.
How we made our composite fuel sump DarkAero, Inc 2022-12-06 | Ever wonder what's needed to make a carbon fiber part? You need a mold, but how do you make a mold?
How infusible cores work DarkAero, Inc 2022-12-04 | How do you create composite parts that are lightweight, strong, and take on a honeycomb look to them?
Why no one wants to paint carbon fiber DarkAero, Inc 2022-11-28 | The traditional process of preparing a composite airplane for paint isn’t enjoyable. We wanted to improve upon that for the DarkAero 1.
Why no one wants to paint carbon fiber DarkAero, Inc 2022-11-24 | Learn how to make your own high-quality carbon fiber parts: darkaero.com/coursesMany questions have been asked about whether the DarkAero 1 prototype would be painted or if the raw carbon fiber look would remain. We chose to paint the prototype for several reasons. Find out why in this video!Start learning about aircraft design and composites today by checking out the DarkAero Knowledge Base: darkaero.com/knowledge/compositesPaint Equipment Used:GORILLASPRO Inflatable Paint Booth 26x15x10Ft: amzn.to/3VntnfDDeVilbiss HVLP Spray Gun, Gravity amzn.to/3Vq5m7WDeVilbiss DeKups Demo Kit amzn.to/3Ovs2S1DeVilbiss DeKups Disposable Cup and Lid, White (24 oz) amzn.to/3Ovs2S1DeVilbiss DeKups Disk Filter - 24/34 oz. Capacity amzn.to/3OB2EtXDeVilbiss DC101 Paint Prep Wipe, (Box of 300) amzn.to/3EZLvqQDeVilbiss Digital Gauge with Air Adjusting Valve amzn.to/3OAr46XDeVilbiss DAD500 3-Stage Desiccant Dryer Unit amzn.to/3EA1af0Quincy QT-54 Splash Lubricated Reciprocating Air Compressor: amzn.to/3EuLLfUJoin the DarkAero YouTube Community for exclusive photos, video, live Q&A, and more!youtube.com/darkaeroinc/joinIf you enjoyed this video and would like to see more of this type of content, follow along as we work to create the fastest, longest-range aircraft you can build in your garage!darkaero.cominstagram.com/darkaeroinclinkedin.com/company/darkaero-inc
Exoskeleton wing design - how carbon fiber makes it possible DarkAero, Inc 2022-10-27 | Sign up for the DarkAero Aerospace Composites Course: darkaero.com/courses/aerospace-compositesOnline course available here: darkaero.podia.com/aerospace-compositesThe wing of the DarkAero 1 is strong enough to support thousands of pounds of lift load while remaining exceptionally light. Part of the secret behind this is it's made from carbon fiber composite. However, there's more to its structure than meets the eye. In this video, we discuss the design of the composite structures inside the wing of the DarkAero 1 and what makes them different. 0:00 - Intro0:18 - Design Requirements1:51 - Lift Load Distribution Defined2:57 - Conventional I-Beam Wing Spars6:11 - The DarkAero "Hollow Grid" Approach7:32 - Advantages of "Hollow Grid"8:52 - Advantages of Using Composites10:15 - Physically Test or Simulate?11:40 - Summary Join the DarkAero Community - youtube.com/darkaeroinc/join(Exclusive members only content including photos, videos, live Q&A and more!) DarkAero 1 Aircraft - darkaero.com/aircraftDarkAero Knowledge Base - darkaero.com/knowledgeDarkAero Apparel - darkaero.com/shopIf you enjoyed this video and would like to see more of this type of content, follow along as we work to create the fastest, longest-range aircraft you can build in your garage!More information on DarkAero can be found on our website and other social media accounts: darkaero.comfacebook.com/darkaeroincinstagram.com/darkaeroinclinkedin.com/company/darkaero-inc
Why we dont use winglets (DarkAero 1 Wing Design) DarkAero, Inc 2022-10-17 | DarkAero Courses - darkaero.com/coursesJoin the DarkAero Community - youtube.com/darkaeroinc/join(Exclusive members only content including photos, videos, live Q&A and more!) If you’re interested in aviation, you’ve probably spent enough time looking at airplanes to notice there's a huge variety in the size and shape of airplane wings. Long wings, short wings, folding wings, swept wings…. if you can imagine it, someone's probably already built it and tested it. But why are there so many different wing configurations, and how do engineers come up with all these designs for airplane wings? Let’s look at the wing design for the DarkAero 1 to begin answering these questions.0:00 - Intro0:28 - Design Requirements1:45 - DarkAero 1 Wing Design2:06 - Lift, Drag, Angle of Attack2:46 - Lift Equation6:18 - Stall Characteristics7:59 - Drag Equation9:16 - Parasitic Drag11:42 - Lift Induced Drag & Winglets13:59 - SummaryDarkAero 1 Aircraft - darkaero.com/aircraftDarkAero Knowledge Base - darkaero.com/knowledgeDarkAero Apparel - darkaero.com/shopIf you enjoyed this video and would like to see more of this type of content, follow along as we work to create the fastest, longest range aircraft you can build in your garage!More information on DarkAero can be found on our website and other social media accounts: darkaero.comfacebook.com/darkaeroincinstagram.com/darkaeroinclinkedin.com/company/darkaero-inc
Making our nose gear come to life - main gear is next DarkAero, Inc 2022-10-03 | We are working on the main landing gear actuation, which will be very similar to the nose gear.
A rudder + air brake in one system DarkAero, Inc 2022-09-30 | The DarkAero 1 uses a split rudder system for integrated yaw control and speed brake functionality.
The engineering required to fly fast (GVT) DarkAero, Inc 2022-09-11 | Learn how to make your own high-quality carbon fiber parts: darkaero.com/coursesJoin the DarkAero Community - youtube.com/darkaeroinc/join(Exclusive members only content including photos, videos, live Q&A and more!) We have been working on ground vibration testing the DarkAero 1 prototype. The objective of this effort is to characterize the vibration mode shapes, natural frequencies, and damping of the airframe. This will help us build a model of the aircraft to predict flutter speeds and ultimately the Vne or never exceed speed of the airplane.0:00 - Intro0:52 - Sam Jaeger1:05 - What is Aeroelasticity?1:36 - Aeroelasticity Fundamentals2:54 - Degrees of Freedom & Modes3:51 - Divergence4:58 - Flutter6:45 - Ground Vibration Testing (GVT)9:25 - Next StepsDarkAero 1 Aircraft - darkaero.com/aircraftDarkAero Courses - darkaero.com/coursesDarkAero Apparel - darkaero.com/shopIf you enjoyed this video and would like to see more of this type of content, follow along as we work to create the fastest, longest-range aircraft you can build in your garage!More information on DarkAero can be found on our website and other social media accounts: darkaero.comfacebook.com/darkaeroincinstagram.com/darkaeroinclinkedin.com/company/darkaero-inc
How carbon fiber varies in quality DarkAero, Inc 2022-08-27 | More info at darkaero.com/courses. If you want to learn how to design composite parts and develop the hands-on skills to build them, then our courses are for you!We have helped students accelerate their progress building experimental aircraft, eVTOLs, drones, UAVs, boats, racecars, electric vehicles, motorcycles, bicycles, and military hardware.
FIRST TAXI TEST! - DarkAero 1 DarkAero, Inc 2022-08-12 | Learn how to make your own high-quality carbon fiber parts! Sign up for DarkAero courses here: darkaero.com/coursesWe recently completed the first taxi test run on the DarkAero 1 prototype aircraft! Prior to the test, there were several preliminary tests that were completed including the first and second static engine test runs. These tests helped us verify that there were no outstanding installation issues with the engine and that all our engine monitoring data was properly functioning. This gave us enough confidence to proceed forward with the first taxi test for the aircraft! It was always meant to be just a machine, but it's starting to feel like something more...Join the DarkAero Community! (exclusive members only content including photos, videos, live Q&A and more!)youtube.com/darkaeroinc/joinDarkAero Apparel - darkaero.com/shopDarkAero Knowledge Base - darkaero.com/knowledgeIf you enjoyed this video and would like to see more of this type of content, follow along as we work to create the fastest, longest-range aircraft you can build in your garage!More information on DarkAero can be found on our website and other social media accounts: darkaero.cominstagram.com/darkaeroinclinkedin.com/company/darkaero-inc
How we built the DarkAero 1 impossibly light... DarkAero, Inc 2022-07-16 | Try Onshape for free at: https://Onshape.pro/DarkAeroOne of the unique aspects of the DarkAero 1 is its light empty weight, which is targeted to be around 750 lbs. We discuss the engineering and manufacturing principles we applied in the development process to achieved this number. Join the DarkAero Community - youtube.com/darkaeroinc/join(Exclusive members only content including photos, videos, live Q&A and more!) DarkAero 1 Aircraft - darkaero.com/aircraftDarkAero Courses - darkaero.com/coursesDarkAero Apparel - darkaero.com/shopDarkAero Knowledge Base - darkaero.com/knowledge00:00 Intro00:32 Weight the Aircraft02:06 Comparing Aircraft Empty Weight Numbers04:05 Smaller is Lighter04:43 More Power Less Weight06:12 Consolidate Integrate Eliminate 07:17 Use Light Materials08:31 Be Precise Be Accurate 09:56 Design for Iteration11:10 Become a Minimalist 12:18 Weigh Everything Track Everything13:38 Every Gram Matters14:22 Recap14:58 Next Steps for DarkAero 1If you enjoyed this video and would like to see more of this type of content, follow along as we work to create the fastest, longest-range aircraft you can build in your garage!More information on DarkAero can be found on our website and other social media accounts: darkaero.cominstagram.com/darkaeroinclinkedin.com/company/darkaero-inc
FIRST ENGINE START! - DarkAero 1 Aircraft DarkAero, Inc 2022-07-04 | The DarkAero 1 first engine start was a success! The DarkAero 1 was designed specifically around the UL520iS engine made by UL Power. More information about this engine can be found at: ulpower.com/en/engines/ul520/ul520isJoin the DarkAero Community: www.youtube.com/darkaeroinc/join(Exclusive members only content including behind the scenes photos, videos, live Q&A and more!) There are a number of tools that we used to get the engine to a state where we could test run it. A big component of this was establishing proper torque values. For this we used a combination of 1/4", 3/8", and 1/2" torque wrenches. These tools along with others that will be needed to build the DarkAero 1 are called out in our Build Tools Page: darkaero.com/knowledge/toolsMore information about the aircraft can be found here: darkaero.com/aircraftSUPPORT DARKAERO: darkaero.com/shopIf you enjoyed this video and would like to see more of this type of content, follow along as we work to create the fastest, longest range aircraft you can build in your garage!More information on DarkAero can be found on our website and other social media accounts: darkaero.cominstagram.com/darkaeroinclinkedin.com/company/darkaero-incShort cut links to some of the most used tools for the engine install: 1/4" Tekton Torque Wrench: amzn.to/3IotiTW3/8" Tekton Torque Wrench: amzn.to/3yLbkI61/2" Tekton Torque Wrench: amzn.to/3uuWvGTTekton 1/4" Drive Socket Set: amzn.to/3yJF1JyTekton Screwdriver Set: amzn.to/3ymaakz
How to set up an aerospace factory DarkAero, Inc 2022-05-29 | For more details on the DarkAero Mold Making Course, please send us an email at: course@darkaero.com. The new shop received its first set of equipment including the DarkAero 1 production molds, a new router, and desks/chairs to teach the Aerospace Composites Course. With the production molds moved up to the new shop, the hangar is a lot more open and easier to work in which has already been helpful as we wrap up work with the DarkAero 1 prototype. There are a lot more tools and equipment we need to bring to the new shop but we are excited to get started! Work is still progressing a long for the DarkAero 1 prototype, and we'll have more to share on that soon. Join the DarkAero Community - youtube.com/darkaeroinc/join(Exclusive members only content including photos, videos, live Q&A and more!) There are a lot of other small tools that will be necessary for pilot production that we didn't get a chance to talk about in this video. Some other tools we plan to use for pilot production:Oscillating Cutter: amzn.to/3s7K8hmOscillating Tool Blades: amzn.to/35PkwfyTorque Wrench: amzn.to/2LwFPevDigital Scale: amzn.to/35lkewCDarkAero 1 Aircraft - darkaero.com/aircraftDarkAero Knowledge Base - darkaero.com/knowledgeDarkAero Apparel - darkaero.com/shopIf you enjoyed this video and would like to see more of this type of content, follow along as we work to create the fastest, longest range aircraft you can build in your garage!More information on DarkAero can be found on our website and other social media accounts: darkaero.comfacebook.com/darkaeroincinstagram.com/darkaeroinclinkedin.com/company/darkaero-inc
Building an Aircraft Factory | NEW Shop Tour DarkAero, Inc 2022-05-08 | In parallel to developing the DarkAero 1 prototype, we are setting up the production facility for DarkAero 1 kits. This is the first glimpse of the future aircraft factory, and we are excited to take you along on the journey!To learn more about our other products and services like our Aerospace Composites Course, check out: www.darkaero.comJoin the DarkAero Community - youtube.com/darkaeroinc/join(Exclusive members only content including photos, videos, live Q&A and more!) DarkAero 1 Aircraft - darkaero.com/aircraftDarkAero Knowledge Base - darkaero.com/knowledgeDarkAero Apparel - darkaero.com/shopIf you enjoyed this video and would like to see more of this type of content, follow along as we work to create the fastest, longest range aircraft you can build in your garage!More information on DarkAero can be found on our website and other social media accounts: www.darkaero.comwww.instagram.com/darkaeroincwww.linkedin.com/company/darkaero-inc
How do we start this thing? | The DarkAero 1 Prototype DarkAero, Inc 2022-05-01 | DarkAero Aerospace Courses: darkaero.com/coursesWe are getting closer to the first engine start for the DarkAero 1 prototype. There are still a lot of little tasks to wrap up before we can. This video covers several of those tasks. Join the DarkAero Community - youtube.com/darkaeroinc/join(Exclusive members only content including photos, videos, live Q&A and more!) We get asked what tools we recommend for working with composites. Here are some of the most common ones we work with: Air Filtration: amzn.to/38ucg6nOscillating Tool: amzn.to/3s7K8hmOscillating Tool Blades: amzn.to/35PkwfyRotary Tool: amzn.to/3skTmXrIf you'd like to learn more about the DarkAero project or would like to support the project, follow one of these links: DarkAero 1 Aircraft - darkaero.com/aircraftDarkAero Knowledge Base - darkaero.com/knowledgeDarkAero Apparel - darkaero.com/shopIf you enjoyed this video and would like to see more of this type of content, follow along as we work to create the fastest, longest range aircraft you can build in your garage!More information on DarkAero can be found on our website and other social media accounts: darkaero.comfacebook.com/darkaeroincinstagram.com/darkaeroinclinkedin.com/company/darkaero-inc
Canopy EJECT Mechanism on the DARKAERO 1 Aircraft DarkAero, Inc 2022-03-25 | DarkAero Aerospace Courses: darkaero.com/coursesLet's take a look at some of the small but critical mechanisms we have been working on for the DarkAero 1 prototype. These include the canopy latch, throttle control, and canopy jettison. Join the DarkAero Community - youtube.com/darkaeroinc/join(Exclusive members only content including photos, videos, live Q&A and more!) We get asked what tools we recommend for working with composites. Here are some of the most common ones we work with: Air Filtration: amzn.to/38ucg6nOscillating Tool: amzn.to/3s7K8hmOscillating Tool Blades: amzn.to/35PkwfyRotary Tool: amzn.to/3skTmXrComposite Basics Book: amzn.to/2MRNxRwIf you'd like to learn more about the DarkAero project or would like to support the project, follow one of these links: DarkAero 1 Aircraft - darkaero.com/aircraftDarkAero Knowledge Base - darkaero.com/knowledgeDarkAero Apparel - darkaero.com/shopIf you enjoyed this video and would like to see more of this type of content, follow along as we work to create the fastest, longest range aircraft you can build in your garage!More information on DarkAero can be found on our website and other social media accounts: darkaero.comfacebook.com/darkaeroincinstagram.com/darkaeroinclinkedin.com/company/darkaero-inc00:00 - Intro00:28 - Keeping the Canopy From Opening in Flight04:31 - How We're Throttling the Engine9:17 - Why Have a Glare Shield?12:28 - The Canopy Jettison Mechanism14:41 - Our Next Major Milestone
This Canopy is DIFFERENT | Hinged and Installed - The DarkAero 1 Canopy DarkAero, Inc 2022-02-15 | An update on the work we've been putting in to both install our canopy and finalize its hinge mechanism. DarkAero 1 Aircraft - darkaero.com/aircraftDarkAero Aerospace Composites Course - darkaero.com/coursesDarkAero Knowledge Base - darkaero.com/consultingDarkAero Apparel - darkaero.com/shopIf you enjoyed this video and would like to see more of this type of content, follow along as we work to create the fastest, longest range aircraft you can build in your garage!More information on DarkAero can be found on our website and other social media accounts: darkaero.cominstagram.com/darkaeroinclinkedin.com/company/darkaero-inc
