Structural Design & Analysis

Preliminary Structural Design and Sizing

We support early-stage vehicle development with rapid, high-confidence structural sizing – using aerodynamic loads, configuration data, and mission requirements to guide material selection and structural layout.

Our services focus on delivering data-rich, traceable results that feed seamlessly into downstream modeling, manufacturing planning, and system integration.

Our capabilities include:

• Material System Selection: Evaluating metallic, composites, and hybrid material systems to meet structural, thermal, manufacturing, and cost constraints
• Structural Sizing: Estimating preliminary required gauges and structural gauges for key load paths
• Generative Design Applications: Leveraging topology optimization and AI-driven design for complex geometries and novel architectures

Typical Deliverables Include:

• A database of material systems and their complete properties, suppliers, and possible substitutes
• Preliminary layout drawings generated to customers specifications
• A database of preliminary structural gauges for fuselage, wing, empennage, and auxiliary members
• Generative design outputs including raw and optimized geometries, design load conditions, and weight trade documentation

Advanced Structural Modeling and Analysis

Once preliminary sizing is complete, we build high-fidelity, parametric models of the vehicle structure to support detailed analysis, integration, and refinement.

These models allow for iterative optimization and seamless integration with flight sciences, propulsion, and manufacturing teams – ensuring that structure supports both performance and production goals.

• Weight and Inertia Analysis: Quantifying structural contribution to weight, CG location, and moments of inertia
• Manufacturability Evaluation: Ensuring parts, joints, and assemblies are production-ready
• Configuration Refinement: Refining the vehicle’s layout to accommodate component integration.
• Stress Analysis and Aero-Elasticity: Simulating structural response under aerodynamic and inertial loads
• Detailed Cost Estimation: Supporting trade studies and program-level budgeting

Typical deliverables include:

• A parametric 3D CAD model of the full structural assembly, delivered to match program requirements and analysis scope

From early trade studies through digital mock-up and design integration, we ensure your structure is optimized for stiffness, strength, weight, cost, and manufacturing – every step of the way.