In September, we concluded the wing proof load testing for the DarkAero 1 prototype with the negative G load tests. We finished the plug that will be used to create the mold for our canopies, and we brought two additional interns onto the team for the fall.

Negative G Proof Load Test
We built upon the wing proof load testing we started in August and conducted the negative G proof load tests in September. These types of tests require a significant amount of planning and setup effort but the test results are invaluable. We modified the positive G test stand so that it could support the wing in the proper orientation for negative G testing. We had to design and machine new foam load distribution pads to support the test weights and supporting jack points. The extruded aluminum frame positioned around the perimeter of the wing to help check deflection was reconfigured for this test as well. We documented the setup for reference in a YouTube video linked here:

How we set up the negative G proof load test for the DarkAero 1 wing!

The negative G tests were conducted using the same methods as the positive G tests, and the whole process ran smoothly. We are excited to report the wing passed this latest phase of testing. The upcoming wing assembly tasks will include final installation of the fuel sump, fuel lines, wing tips, lights, pitot tube, and pitot-static lines. 

Custom Communication Antenna Testing
We have been continuing with embedding all the antennas in the DarkAero 1 to keep the design as aerodynamically and aesthetically clean as possible. To accomplish this for our communications antenna, we have been experimenting with a custom design derived from the following journal paper: 

An Airborne VHF Printed Monopole Antenna for Platform Constrained Applications

We have been using a vector network analyzer to test our initial design prior to flight testing. This tool allows us to measure the efficiency of the antenna design and make changes in order to achieve more efficient signal transmission. We plan on making a more formal version of this prototype that can be attached to the inside face of the canopy fairing prior to flight testing. 

Wiring Progress
The first set of Click Bond studs and clamps were added to the pilot side area of the cockpit to hold our wiring harness off the airframe.  We have also been adding flame resistant expandable sleeving in areas of the wiring harness where more abrasion could be present such as the hinge point of the instrument panel and the corridor between the wing and the fuselage. In the coming weeks we will continue working our way back through the fuselage aft of the cockpit to install additional fasteners to hold the harness in these areas. 

Introduction to New Interns: Michael Wirsing and Nathan Moser
We brought two new interns onto the team this month, Nathan Moser and Michael Wirsing. 

Nathan is starting his senior year at Northern Illinois University and will be graduating in the spring with a B.S. in Mechanical Engineering. Nathan has quickly gotten involved in several projects. He assisted with the setup of the latest wing proof load tests. Currently he is working on installation and plumbing of the fuel sump in the aircraft. Nathan has interests in flight testing so he has also been assisting with the flight test planning. 

Michael is a recent graduate from Embry-Riddle Aeronautical University and is also a flight instructor. Michael is currently living in Florida and is working remotely helping to develop useful information for the DarkAero Knowledge Base. He has already created a new interactive tool on additive manufacturing. It provides a high level overview of the major additive manufacturing processes, materials, and proper design practices. This new tool is now available for use on the DarkAero Knowledge Base:

View the Additive Manufacturing Knowledge Base

Michael will also be helping us write and edit build instructions for the DarkAero 1 kit. 

Canopy Plug Work
We finished our new canopy plug which will be used as a pattern to create a new mold for the thermoformed canopy. Back in August we worked with Airplane Plastics to finalize the canopy mold design and began machining out the stock sections for the new plug. In September we completed all the finish machining work on the plug sections as well as its overall assembly and contouring. With the plug completed, we can proceed with manufacturing the final canopy mold in October. We are optimistic about how the new canopy work has been progressing, and we are excited to share the prototype canopy in the coming weeks. 

Airmaster Propeller Controller
We were able to have the propeller controller sent in advance while we await the manufacture and shipment of the Airmaster Propeller. The specific controller we selected is the AC-200F unit from Airmaster. We began the process of installing this portion of the propeller system into our instrument panel and integrating it with the rest of the electrical system. We will be able to fully complete the system installation once we receive the propeller in the coming weeks. 

DarkAero Multitool
Keegan performs the majority of the machining work at DarkAero, and to eliminate this potential bottleneck for future machining tasks, we came up with an efficient way to teach the rest of the team how to use our CNC mill.  Over the course of a weekend, each team member spent some time with Keegan machining their own multitool. We had a lot of fun getting everyone more comfortable with the process of machining parts. We produced several extra multitools and decided to offer these for sale on our shop page. Besides being useful as a teaching tool for machining, the multitool is able to hold its own in everyday use.

If you are interested in getting one of these multitools for yourself, there is a limited run available now on our shop page:

DarkAero Multitool Shop Page

As a self-funded team, each purchase goes directly towards bringing the DarkAero 1 to market! 

YouTube Membership
We recently launched our YouTube membership program for those that want to help support our mission to bring the DarkAero 1 to market and grow interest in engineering, manufacturing, and aerospace. Those who join can access a library of exclusive bonus content including photos and videos, behind the scenes footage, and live Q&A sessions. We are excited by how much the community has grown so far, and we are looking forward to sharing more bonus content with members. We thank everyone who has joined, and we encourage others to join if you are interested in actively supporting DarkAero! Use the following link to become a member today:

https://www.youtube.com/darkaeroinc/join 

In the Press
We were contacted in September to do a video call with the University of Wisconsin-Madison Badger Flying Team to talk about the journey of starting and DarkAero. Ryley gave the presentation and answered many questions about technical challenges, composites manufacturing, testing, and design.

Avid CNC invited us to do a customer live stream on their YouTube channel since we use one of their routers to cut out the ribs, shear webs, and bulkheads in the DarkAero 1. Additionally, we used our Avid CNC router to machine every single mold pattern for the aircraft. In the live stream we talked about machining mold patterns, machining carbon fiber, dialing in the router, and a lot of other interesting topics. If you want to view the talk, the link is provided below:

Live with DarkAero - Airplane Kit Manufacturing Company

DarkAero YouTube
We released a number of public videos in September including some exciting progress updates and the much anticipated video about galvanic corrosion! If you have not watched these yet, you can find them all on our YouTube channel:  www.youtube.com/darkaeroinc

Looking Ahead
In October we will be working on the remaining wing assembly tasks, collaborating with Airplane Plastics to build the final canopy mold, finalizing the wiring harness installation, and manufacturing components for the main landing gear. There are more technical videos and progress updates we are planning to release soon so stay on the lookout for those!