Personal Project
Dec 2025 – Jan 2026
Project Overview
This personal project focused on the design of a telescoping, shock-absorbing landing gear system for a 3.5-lb RC sport aircraft. The goal was to reduce impact loads during landing while maintaining structural integrity, low weight, and manufacturability.
The landing gear was designed to safely absorb approximately 11 lb landing loads with 1.5 inches of stroke and a factor of safety of 2.5, applying fundamental mechanical design and analysis principles.
Design Objectives
- Absorb landing impact loads to protect the airframe
- Maintain low weight and compact geometry
- Ensure structural reliability with an appropriate safety factor
- Design components suitable for fabrication and assembly
Engineering Design & Analysis
Shock Absorption System
- Designed a telescoping landing gear mechanism using nested aluminum tubes
- Integrated a compression spring to dissipate landing energy and limit peak loads
- Targeted smooth load transfer during impact while preventing bottom-out
Spring Selection & Calculations
- Performed spring rate calculations to determine appropriate stiffness and travel
- Designed for a spring rate of approximately 7.5 lb/in, using 0.048-inch music wire with 24 active coils
- Verified performance to meet landing load requirements and stroke constraints
Structural Design
- Selected 6061-T6 aluminum for the telescoping tubes due to strength-to-weight ratio and machinability
- Designed tube dimensions and clearances to ensure smooth telescoping motion and structural stability
- Applied a 2.5 factor of safety to all critical load-bearing components
CAD Modeling & Documentation
- Created detailed SOLIDWORKS CAD models of all landing gear components
- Applied DFM/DFA principles to optimize geometry for fabrication and assembly
- Produced engineering drawings with verified dimensions and tolerances
Results
- Achieved a calculated spring rate of 7.48 lb/in, meeting design targets
- Verified that the landing gear could safely absorb expected landing loads
- Final design met all structural and performance requirements with the desired safety factor
- Project documentation and final design refinements are currently being completed
Tools & Skills Applied
- SOLIDWORKS (CAD modeling, assemblies, drawings)
- Mechanical design and structural analysis
- Spring rate and load calculations
- Design for manufacturability and assembly (DFM/DFA)
- Material selection (6061-T6 aluminum)
Key Takeaways
- Strengthened understanding of shock absorption and impact loading
- Applied mechanical analysis to a real, performance-driven design problem
- Developed confidence in end-to-end design ownership, from calculations to CAD
- Gained experience balancing performance, safety, and manufacturability
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