In January, several major testing milestones were achieved on the DarkAero 1 prototype. These included completion of the final phase of landing gear drop testing, as well as completion of landing gear side load and brake load tests. In parallel, work continued on customer projects to design, build, and test airframes and systems. Additionally, the hiring process continued for both manufacturing technicians and engineers.

Drop Testing
The final phase of main landing gear drop testing was completed in January. This marked the culmination of several months of work to explore the capability of the DarkAero 1 prototype landing gear structures across a range of hard landing conditions. A number of changes were made to the landing gear and airframe structures over the entire test campaign, and several major updates materialized in the final phase of testing. 

Three of the major updates that were made during the last phase included lengthening the main gear struts, modifying the upper shock mount, and implementing a fifth design revision of the trailing links. These changes were made to increase the amount of energy absorbed by the shocks during nose-high landings and also to allow for longer shocks to be installed to further reduce landing loads on the airframe.

One of the recurring themes throughout the drop testing campaign has been the value of obtaining physical test results. With each test, the behavior and performance of the landing gear were more thoroughly characterized, allowing the team to anticipate and implement the next set of design revisions. 

The drop testing campaign provided a controlled approach to refining the landing gear design and ensured it met airworthiness criteria. By gradually increasing drop heights and testing across different pitch angles, it was possible to systematically evaluate performance and implement necessary design improvements. Inspections were conducted after each drop, guiding iterative changes to optimize the strength and energy absorption of the landing gear. In total, over 125 drops were performed on the DarkAero 1 prototype, leading to more than 15 significant design updates that shaped the final configuration for flight testing.

A new video summarizing the entire testing campaign will be released on the DarkAero YouTube Channel. Stay tuned for this in the coming weeks! 

Side Load Testing
After completion of the drop testing campaign, the team transitioned to conducting the remaining landing gear load tests to simulate the range of landing loads the DarkAero 1 might encounter.

The landing gear side load test simulated lateral loads on the main landing gear, which could occur during a crosswind landing if the airplane touched down while being yawed away from the runway centerline. The test setup involved loading the airplane up to a target weight above the gross weight of the aircraft and applying a force directly sideways on both main landing gear. A strap, turnbuckle, and load cell were used to apply loads, and both main gear were placed on automotive dollies to allow them to slide freely sideways. The scope of this test was much more limited compared to drop testing, and the landing gear passed without major events.

Brake Load Testing
The last test on the landing gear structure completed in January was brake load testing. This test was designed to simulate the loads on the airframe during an aggressive braking operation. Simulated braking forces were generated by gradually applying loads to the gear from the base of the wheels through straps and turnbuckles, while simulated inertial loads reacting the brake loads acted through a strap around the engine mount. 

Load cells, connected in series with the turnbuckle, were used to provide feedback on the amount of load being applied. 

Throughout the course of conducting side load and brake load tests, no major issues were detected and no additional design changes were made to the airframe or landing gear. A contributing factor to the rapid progression through these tests came from landing gear and airframe modifications that were implemented previously during drop testing.

Courses
Session 24 of the DarkAero Aerospace Composites Course will be held on March 27-28. Since the last session, new hands-on prepreg demos have been added to the curriculum, as well as more in-depth information on composite repair and manufacturing composites in a scaled production environment. 

If you are interested in learning how to integrate aerospace composites into your designs and develop the hands-on skills to build them, this course is for you! Only three spots remain in the March 27-28 session, so reserve your spot now using the link below:

Sign up for the DarkAero Aerospace Composites Course

DarkAero Careers
DarkAero is continuing to grow the team! Applications for manufacturing technicians and engineers are currently being accepted. Individuals with a strong work ethic, hands-on skills, and a desire to work on challenging projects are an ideal fit at DarkAero. If you want to be part of a dedicated team designing and building new aircraft, check out the DarkAero Careers page and apply today!

DarkAero Careers

Looking Ahead
In February, the team will conduct proof load tests on the wing-to-fuselage interface. While the wing itself has already been proof loaded, the connection points where the wing interfaces with the fuselage still require proof load testing. Planning of this test campaign has already begun, and the testing itself will commence in the next week. Expanding the team and increasing manufacturing capacity will remain a focus.