Design

Using state of the art 3D CAD systems, we can bring your ideas from concept to reality. With a strong link to manufacturing partners we design, build and integrate parts and assemblies.

Optimizing use of materials

Light Weight Solutions

Material is weight. With good design practices, experience and numerical methods, we optimize the use of materials to carry load or provide stiffness where needed. 
With a strong heritage of ultra-light weight aircraft (Solar Impulse, Aurora HAPS, Boeing eVTOL) our team possesses the tools and knowhow to fully optimize structural solutions and save weight. 

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Computer Aided Design

Advanced 3D CAD Modelling

Depending on needs we can provide the full range of design services:

  • Integrated and tested assemblies

  • Installation drawings

  • Manufactured parts

  • Manufacturing drawings (2D or 3D FT&A), ISO or ASME standards

  • 3D models

Manufacturing

Flexible Manufacturing Options

With a network of supplier companies we efficiently source any type of composite or metallic parts. We provide tooling and manufacturing support. When and where possible, we do assembly, integration and testing efforts in-house. 

Finding solutions

Repairs and Modifications

Repairs and modifications need critical eyes and creative minds. The integrity of the load path while maintaining functionality is key. At Axalp we provide the solution, the analysis and the implementation, depending on your need. We look forward to receiving any requests.

Tools and Methods

  • CAD: NX, CATIA V5

  • Parametric and robust CAD models

  • Use of 3D printing for rapid prototyping to prove form, fit and function

Structural Analysis

Analytical methods essential to maximize safety and minimize risk and prevent expensive failures further down the development cycle.  We master the full range of analysis, from simple static part checks to mode interaction, to aeroelastic coupling, and more.

Static Analysis

  • Linear static analysis (strain, stress, deformation)

  • Non-linear static analysis for highly deformed structures or non-linear material behavior

  • Stability analysis (buckling)

  • Nominal and transient thermal analysis

Dynamic Analysis

Including time and frequency domains, this advanced type of analysis is used for events such as: 

  • Impact analysis

  • Shock landing

  • Crash

  • Rotor-dynamics

  • Aeroelastics

Dynamics as core competence

Advanced Dynamic Analysis

Designing structures in vibration environments including coupling and fluid interaction is challenging. At Axalp have core competence in this field. Our domains of expertise are:

  • Identifying and analysing induced vibrations

  • Structure-fluid coupling (static or rotating environment)

  • Aeroelastic analysis: flutter and divergence, static and transient responses

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Loads and boundary conditions

Loads and Requirements

We provide analysis of load cases and can support load case definitions based on industry standards, and FAR/CS regulations for aviation. 
For aerodynamic and structure loads we use tools such as:

  • OpenFOAM

  • XFLR5

  • ASWING

  • Internally developed tools

Loads Case Selection

External loads are typically defined by standards and often rigid-body physics. Internal loads are typically derived by geometry, stiffness and inertia. At Axalp, we provide the whole loads suite: definition, load case selection, loads envelops. Were necessary, we build stiffness representing stick models or GFEM models to identify internal load distributions and interface loads. These type of tools allow load sweeps and provide an efficient way of covering and sizing for all load scenarios. 

  • Aerodynamic loads

  • Ground loads

  • Inertia loads

  • Abuse loads

  • Crash loads

External Loads

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Internal Loads

  • Distributed internal loads (force, moment, torque)

  • Interface loads
     

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Performance 

Optimization

In structural typical performance indicators are ratios such as strength to mass, stiffness to mass, mass to cost etc. With a deep understanding of material properties, options and manufacturing techniques, we can efficiently point out means to increase the indicators you need. 

Sizing for vibrations and long life

Fatigue

Vibrational environments pose a significant risk on parts. Often these are components in proximity of propulsion systems, gears and rotating blades. We cover the full set of analysis methods:

  • Stress life method analysis – high cycle fatigue domain

  • Strain life method analysis – low cycle fatigue domain

  • Crack propagation analysis – Prediction of parts failure subjected to defects

  • CFRP Multiaxial fatigue - Estimation of residual stiffness and residual strength

Solutions Axalp can provide:

  • Service life definition

  • Inspection interval definitions

  • Consulting on best-practice and design improvements

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Tools and Methods

Software:

  • General CAE Systems: NX Nastran, LS-Dyna

  • Pre- and Postprocessor: FEMAP

  • In-house MATLAB tools

Methods:

  • Frequency and Time Domain – NASTRAN SOL103/110 (Modal Domain), SOL108/111 (Freq. Response) and SOL109/112 (Time Domain)

  • Aeroelastic analysis – NASTRAN SOL144-146 

  • Shock, Crash, and Bird Impact – LS-Dyna (explicit) or Excel tool

  • Rotor dynamics – NASTRAN, DMAP, MATLAB, and LS-Dyna