Overview
Flugtag was a design and build competition held by Red Bull. A group of friends and I designed and built a vehicle that could be pushed off a ledge, releasing a glider that would fly into the water. The goal was to glide the furthest distance possible. This competition was a fun way to apply the engineering knowledge we had acquired in school.
Technical Challenges
- Building with Limited Equipment: We completed the build in a friend's garage using limited tools. Instead of CNC, we used a handheld hot wire cutter to shape foam ribs and PVC piping to construct the body due to lack of machining tools.
- Lack of Testing: Because the vehicle would be destroyed after the competition, we built only one and relied on CAD modeling and calculations to plan it effectively.
- Human Pilot: The glider had to carry a real person. We had to ensure structural integrity while maintaining a safe ejection mechanism.
Design & Testing Methodologies
We used simulation software in Fusion 360 to test the strength of the wings and overall frame. We also referenced images from previous Flugtag teams to benchmark our design and safety concepts.
Tools used: Fusion 360, SolidWorks, Excel/VBA, hand tools, hot wire cutting, 3D printing, and physical prototyping.
Solutions and Results
- Limited Equipment: We adapted by selecting materials that required minimal machining.
- Lack of Testing: Our simulations and modeling replaced physical prototyping, saving time and resources.
- Space to Build: We organized four distinct work areas to streamline the build process.
- Human Pilot: Simulation tools helped us design a structure capable of safely holding a rider during flight and splashdown.
Reflection
You can create impressive projects with minimal materials. It would be beneficial to build several prototypes to better test their strength and flight capabilities. I enjoyed participating in events that allow me to apply my experiences. Projects like this are the kind of work I want to support in the future in my own fabrication shop.