1. Executive Summary
June moved Project Spearhead from the May validation and tooling baseline into PT1 integration and manufacturing preparation. The project made progress toward a buildable prototype through electrical architecture planning, structural design closure, flight-model integration, material-process decisions, and continued Stork testbed readiness work. Phase 1 remains focused on electric VTOL and airframe validation, with the main July carryovers being final structural freeze, electrical bench validation, hardware manufacturing, first flight test, and control-surface data needed for stability closure.
2. Project Progress
Team Formation
| Member | Experience Level | Team | Weekly Commitment (hrs) | Areas of Expertise / Championed |
|---|---|---|---|---|
| alperenag | Level 5 | Core | 32 | Project Lead |
| Erick | Level 4 | Core | 15 | Electrical Layout & Avionics |
| Zeynep | Level 4 | Core | 30 | Flight Mechanics |
Progress Overview
June was an integration and manufacturing-preparation month. The flight dynamics model started using the delivered aerodynamic database and added the simulation, trim, linearization, plotting, and test scaffolding needed for stability work. Electrical planning moved toward a PT1 architecture built from off-the-shelf distribution and regulation hardware rather than a custom PCB. Wing and control-surface work narrowed around plywood ribs, hinge support, removable hinge concepts, carbon-tube handling, and first manufacturing steps. Local fabrication work also covered landing-gear plates, hatch-latch CAD, plotting/printing workflows, and material-process trials. The remaining blockers are final structural freeze, control-surface deflection aerodynamic data, servo/regulator closure, and bench validation of the PT1 electrical layout.
3. Major Studies
Flight Dynamics Model and Stability Work
The first ADB-backed flight dynamics model was added with a Python 6-DOF model, ADB v1.1 loading, force/moment conversion, trim scripts, open-loop simulation, plotting utilities, and tests. Initial runs were credible and did not show alarming stability behavior, but control-surface increments remain provisional because the current aerodynamic database does not yet include deflection sweeps.
PT1 Electrical Architecture
The PT1 electrical direction stayed focused on off-the-shelf hardware. Planning covered 12S distribution, candidate PDB/regulator paths, servo power, CAN layout, tail electronics, telemetry, wing-panel connectors, and simplified prototype disconnects. Tail-side electronics and servo regulation remain the main closure items because long low-voltage runs and nearby ESC power wiring create voltage-drop and EMI risks.
Electrical Master | PT1 Planning | PT1 Information Note | Parts List
Wing Structure and Manufacturing Preparation
Main-wing and control-surface rib modeling continued while the hinge detail remained the key structural blocker. The hinge concept moved toward distributed pinned hinges tied into local hardpoints and a plywood hinge/support member, with removable or replaceable hardware kept as a maintainability goal. Manufacturing preparation covered 4 mm plywood sourcing, laser-cut rib planning, carbon-tube cutting guidance, landing-gear plate and box-gear concepts, and first wing/boom quick-release joint concepts based on clamped plates, sockets, and positive retention.
Replaceable Printed Skin Design and Process Trials
The skin concept was updated from a fabric-covered surface to removable 3D-printed panels. Each skin panel is intended to attach to the underlying structure, be removed for inspection or repair, and be reinstalled or replaced without rebuilding the primary structure. This makes the prototype skin a maintainable subsystem and allows damaged or revised panels to be swapped during development.
ASA-Aero remained the selected printed-skin material direction, and the June trials focused on finding a reliable best practice for that material rather than comparing ASA-Aero against PLA-Aero. Early ASA-Aero attempts showed that sparse infill inside thin aircraft skin geometry can break into loose strands and contaminate the perimeter, so the process was iterated around shell geometry, perimeter behavior, drying, enclosure, speed, overlap, retraction, and temperature. A workable ASA-Aero process was eventually found and skin printing started; if ASA-Aero stock runs out, the remaining skin panels will continue with PLA-Aero, making the Phase 1 printed skin a mixed ASA-Aero and PLA-Aero build.
Aerodynamic Database Maintenance and Tool Packaging
The delivered aerodynamic database remained the technical baseline while reference data and Nondimit packaging were cleaned up. June updates included refreshed ADB reference CSV content and a more organized Nondimit package layout with platform-specific launcher/build assets. The next aerodynamic-data need is still the control-surface deflection database for flight dynamics and stability closure.
Aerodynamic Database | Nondimit
4. Goals for Next Month
- Finalize the Spearhead PT1 structural design.
- Finalize the Spearhead PT1 electrical design and bench-test the power/regulator path.
- Manufacture and assemble PT1.
- PT1 first flight test.
- Generate control-surface deflection aerodynamic data for the flight model.
- Update the flight dynamics model with deflection data and complete preliminary stability analysis.
5. Budget & Resource Allocation
Project Expenses
Reimbursements totaling $3140.91 were submitted this month, covering CAD subscription and tokens, Pixhawk 6C and PM02 hardware, Matek CAN/power/PDB hardware, tail servos, a voltage regulator, balsa/plywood/hardware, sheet cutting, lumber, rivet-nut tooling, M3 inserts, 7075 aluminum plates, and PLA/ASA Aero filament. The breakdown can be found here.
Team Members Compensation
Team compensation totaled $21120.00 this month. The breakdown can be found here.
Total
The total June expense of Project Spearhead was $24260.91.