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UAV Wing Box Quick Disconnect Demonstration
Wing Box to Fuselage Connection
Modular Wings System
To optimize assembly efficiency and transport logistics, my team and I designed a modular wing system for a UAV featuring a detachable wingbox and a quick-release snap-fit mechanism. Previously, the aircraft's physical dimensions required extensive transport logistics; disassembling the press-fit and bolted wings and tail section from the fuselage was a multi-hour process. We aimed to eliminate this bottleneck by introducing quick-disconnect interfaces for both the wings and the empennage, which simultaneously streamlined aerodynamic flight testing for various wing profiles and airfoils.
The final architecture utilizes a central wing box anchored to the internal aircraft bulkheads via commercial-off-the-shelf (COTS) draw latches. The wing spars slide directly through the wing box, securing the main wing assemblies via custom 3D-printed snap-fit extrusions integrated into the outer wing ribs.
Key Contributions:
Concept Generation & Research: Spearheaded the conceptual design for the COTS latching integration and the snap-fit attachment method after conducting feasibility and trade studies on various quick-disconnect mechanisms.
Design & Communication: Presented technical research and design iterations at the annual Preliminary Design Review (PDR).
CAD & Prototyping: Collaborated with team members to develop multiple CAD iterations of the wingbox structure using SolidWorks.
Fabrication & Assembly: Laser-cut the wooden structural components and assisted in the final assembly and integration of the 3D-printed wing snap-fit mechanisms.
Wing - Wing Box Snap Fit Fastening Concept
Final Wing Box/Snap-Fit Assembly
Snap-Fit Components on Wing Ribs
Airborne Aircraft during Flight Test
Manufacturing Process
Manufacturing Process
Concept Generation
Debriefed on assembly-time bottlenecks and established project design criteria.
Collaborated in cross-functional team brainstorming sessions to explore potential structural interfaces.
Conducted trade studies on multiple design concepts (e.g., hinged openings, seatbelt latching mechanisms, and integrated snap-fits) to evaluate mechanical feasibility.
Selected a final architecture consisting of a fuselage-mounted wing box latch mechanism coupled with an independent snap-fit wing attachment system.
Detailed Design & Iteration
Sketched initial mechanical layouts and structural concepts.
Calculated operational flight loads applied to the wing roots to determine structural requirements.
Sourced COTS latches rated to meet mass limits and structural force demands.
Partnered with the airframe sub-team to design a lightweight wingbox compliant with envelope, load, and mass budgets.
Modeled the initial wing box assembly and internal components in SolidWorks.
Maintained agile communication with the airframe team, continuously updating CAD geometry to reflect frequent fuselage and payload interface modifications.
Final Assembly & Integration
Fabricated internal frame components: Laser-cut wooden brackets to achieve a high strength-to-weight ratio for the aircraft's internal structural frame.
Sourced standard hardware: Procured commercial-off-the-shelf (COTS) draw latches and threaded fasteners (nuts and bolts) to ensure secure, repeatable mechanical fastening.
Executed physical integration: Assembled the structural sub-assemblies using the specified mechanical fasteners and aligned mating components.
Integrated custom wing interfaces: 3D-printed custom snap-fit attachments and bonded them to the structural wing ribs using a high-strength epoxy adhesive.
Completed full-system integration: Utilized the integrated draw latches and snap-fit mechanisms to securely mate the modular wing assembly to the primary fuselage.
Testing & Validation
Simulated aerodynamic flight loads: Developed a static load test rig using suspended weights to simulate in-flight bending moments and aerodynamic forces on the wing box.
Validated structural integrity via flight testing: Conducted physical flight testing to verify the structural performance of the modular wing system, yielding successful aerodynamic results with zero mechanical complications or structural failures.
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