Development, Rapid Prototyping, and Validation of a Landing Gear System for an eVTOL Demonstrator

Kurzfassung

The development of electric vertical takeoff and landing (eVTOL) vehicles presents significant challenges, particularly in the control engineering of the transition phase from vertical flight to wing-borne forward flight. In the event of a failed transition, a parachute can be deployed. For the remaining kinetic energy, a landing gear system capable of safely absorbing impact forces during landing, including in crash scenarios, is essential. This thesis focuses on the design, rapid prototyping, and validation of a landing gear system for a tandem tilt-wing eVTOL demonstrator developed by the German Aerospace Center (DLR). A methodical approach was adopted, beginning with a comprehensive comparison of skid and wheeled landing gear configurations, followed by the establishment of a detailed requirement list, partially based on European Union Aviation Safety Agency (EASA) guidelines. Various dampening systems, including linear struts, rotating dampeners, and rubber dampeners, were evaluated for their effectiveness in energy absorption and structural integrity. Through an iterative design process enabled by 3D printing, multiple landing gear prototypes were developed and tested. The final design integrates rubber dampeners with carbon fiber legs, achieving the required impact absorption while maintaining low weight and manufacturability. The landing gear system was validated through static load tests and dynamic drop tests, showing promising results in terms of durability and performance. This work demonstrates the feasibility of using rapid prototyping in the iterative development of critical eVTOL components, offering a practical solution to the challenges of safe landing gear design.