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19 Mar 2008  -  New Zealand

Kit plane made with marine Composites technologies

© High Modulus

By applying its marine expertise to an aviation project, High Modulus has in turn incorporated ideas from the aviation sector into its own design methodology.

Entrepreneur Lapo Ancillotti approached High Modulus in 2004 and asked whether the company could help him with his latest project. Whilst Ancillotti was known for his involvement with the management of yachting projects, this new venture aimed to develop a high-performance experimental kit plane suitable for amateurs to build as simply as possible.

This presented a number of challenges not least because to qualify as an amateur builder you must construct at least 51% of the plane yourself; yet Falcomposite, the company founded to develop the concept, wanted to provide the kit in as few parts as possible. They turned to the successful use of composite technology in the marine industry as a model to achieve this.

The design of the Furio is based on the Falco (the Italian word for ‘Hawk’), a more complex timber plane which was a concept designed by Stelio Frati and developed by Luciano Nustrini in the 1950s. Nustrini’s sons, Lapo and Giovanni, are partners with Ancillotti in Falcomposite, and were heavily involved with the final design of the Furio, ensuring that the original concept of a sleek Italian-designed high performance plane was maintained.

The involvement of New Zealand-based composite specialists, High Modulus, Mick Cookson and Marine Excellence, from the outset, meant that the concept could be approached with fresh eyes. Other kit planes do use composites, but they are often complex to build, lack quality control, and consist of thin skins with lots of framing – an approach applied by engineers used to developing metal structures, rather than composite design specialists.

The High Modulus team’s aim was to design a monocoque structure, but with detachable wings so the whole kit is capable of fitting in a 20ft container. The fuselage, wings and tail were designed to enter the kit completed, so amateur builders have confidence in the critical structures, and can focus on bolting the parts together. This monocoque approach is just one of the ways in which the Furio plane differentiates itself from traditional aviation structures, which are typically more complex assemblies.

High Modulus teamed with ANZES (Air New Zealand Engineering Services), with whom they are co-operating separately on a multi-million dollar, multi-year “Research for Industry” project funded by FRST, and through this gained an insight into the differences between aerospace and marine design methodology. Of particular interest was the approach to statistical analysis of mechanical tests, and the similarities between the load bearing on wings and that on the centerboards of canting keel boats. As a result of this collaboration, High Modulus now has the capability to perform its materials and laminate tests to US Military Standards, which are recognized around the world; and a more in-depth understanding of the shock load and pressure distribution in dynamic loading of daggerboards on canting keel yachts.

The various Furio components of the fuselage, wings, tailplane and control surfaces were each approached individually to establish the best manufacturing method to suit the geometry and laminate requirements. The majority of the components were infused carbon fibre with PVC foam cores.

The first plane was publicly unveiled in Auckland in early February, with kits 2 and 3 already in build.

About High Modulus
High Modulus is a world leading composite technology, materials and structural engineering company. With a pedigree stretching nearly 30 years and over 3000 projects, the company has offices in New Zealand, Australia, China and Europe. As well as providing engineering services to a full range of marine applications, High Modulus supplies composite materials and the B3 SmartPac solution to industrial and other sectors in various countries around the world.

About Falcomposite
Falcomposite was established in 2005 with the goal of revolutionizing light aircraft construction. The company assembled an international team of leading innovators in advanced composite construction and aeronautical engineering to develop the Furio LN 27 RG., which also has the support of the New Zealand Government’s Foundation for Research, Science and Technology.

Source : High Modulus