Design process and manufacturing of an unmanned blended wing-body aircraft

Abstract

The design process, the dimensioning, the proof and the manufacturing of a blended wing-body configuration aircraft with diamond shape is presented. The open collaboration project Sagitta is initiated by Airbus Defence and Space with the objective to investigate innovative aircraft configurations for future unmanned aerial systems (UAS) and the therefor necessary technologies. In cooperation of the German Aerospace Centre (DLR) and the Technical University of Munich (TUM) the aircraft structure is realized. A brief project overview points out the objectives of Sagitta and summarizes the characteristics of the extremely lightweight carbon fibre structure. This work focusses on the computation of loads, the process of structural sizing, the simulation-based mainly structural proof and the manufacturing. Particular attention is paid to the specifically developed semi-analytical method for dimensioning adhesive joints. Basing on the detailed finite element model of the global structure, the applicability of adhesive joints as major structural joining variant is proven. The manufacturing process from single components to the assembly of the overall aircraft concludes the realization of the Sagitta demonstrator structure.