In January, thorough ground testing and ongoing refinement of the DarkAero 1 prototype remained a focus of the team. The testing identified several minor issues that are in the process of being resolved. Efforts to expand the team continued, and additional facility space was explored for kit production and contract manufacturing.

Ground Testing
A number of proof load tests were conducted on the control system of the DarkAero 1 prototype to simulate aerodynamic flight loads and ground gust loads. The complete systems for the flaps and ailerons were loaded to observe the response of the control surfaces, hinges, linkages, bearings, and their support brackets. Several areas within the flap and aileron systems were identified with unacceptable levels of compliance. These areas were reinforced to increase their stiffness and safety margins. The flap and aileron systems will be reassembled for continued ground testing in February.

The ailerons were also rebalanced last month, both statically and dynamically, in preparation for flight testing. Balancing control surfaces is a good countermeasure to reduce the potential for flutter at high speeds. The ailerons had a basic level of balance established during their construction, but the application of primer paint altered their balance state.

Landing Gear Retract 
Last year, testing was performed on the retract mechanism for the main landing gear. Out of this work, improvements to the design of the emergency release mechanism were developed to make this system more reliable under a range of potential flight conditions. The parts for the revised emergency release mechanism were ordered, and the work to finish validation of the emergency release for the main gear will continue in February.

DarkAero Growth
DarkAero is growing to accelerate flight testing the DarkAero 1, manufacture DarkAero 1 kits, and expand engineering and manufacturing services. Interviews for new engineer and technician roles within DarkAero are underway. If you’d like to join the team and contribute to advancing the frontier of aerospace, check out the DarkAero Careers page and apply today! Interested candidates can inquire at careers@darkaero.com.

In parallel with the team expansion, DarkAero is strategically pursuing additional shop space to meet the increasing demand for composites manufacturing work and DarkAero 1 kits.

Aerospace Composites Course
Session 21 of the DarkAero Aerospace Composites Course was held in January, and each session brings a new group of students with unique applications. While students in the last session were interested in composites for use in aviation, marine, and sporting goods projects, composite repair has remained a universal topic of interest. The course module on composite repair has continued to advance, and it has also been added to the online version of the course to allow past students to access the new material.

The next session of the DarkAero Aerospace Composites Course will be held on March 22-23. Sign up for the course using the link below:

Sign up for the DarkAero Aerospace Composites Course!

In addition to the Aerospace Composites Course, the next session of the Aerospace Mold Making Course will take place on February 22nd - 23rd. Only 3 spots remain. Sign up by following the link below:

Sign up for the DarkAero Aerospace Mold Making Course!

Looking Ahead
In February, the team will continue working through the remaining ground tests for the control system and structures of the airframe. The main landing gear drop test and load test of the wing to fuselage interface are also on the horizon. Expanding the team and getting new team members up to speed will remain a focus.