Production Engineering Progressing Well

February 23, 2024

The Switchblade flew last November and flew very well! The overall aerodynamics, flying qualities, slow speed handling, take off characteristics, landing ease, and more were just what we had hoped for. We have seen an increase in the desire to have more useful load and a bigger gas tank, and we did not hit our speed goals during test flight. So, besides working out how to make thousands of Switchblades, and making them easy to maintain, we really only had two areas that needed improvement before we begin production:

  1. Thrust and drag improvements to the ducted fan propulsion system to allow attainment of our speed goals.
  2. A bigger wing to allow more useful load and lower landing speeds.

Both areas are being worked on to tweak the design to be better, and we are meeting with success in all areas. This newsletter we will concentrate on the wing design.

Bigger Wing & More Useful Load

Probably the biggest challenge faced by the Team was to increase the useful load and decrease our landing and take-off speed. Normally these would be opposing each other. More success for one would mean less success of the other. What we sought was a solution that would allow both features to be accomplished. 

We sought out highly qualified and specialized engineers and listened to their input and design ideas to add to our in-house engineering skills. Our in-house skills have increased greatly the last eight months, and we have validated our Computational Fluid Dynamics (CFD) work against both wind tunnel data and actual flight data of our present prototype. CFD is like a wind tunnel in a computer and allows engineers to fine-tune a flying vehicle earlier in the design stage.

Again, we looked at several layouts and approaches to this to gain sufficient data to make decisions on the best way to proceed. One consideration was to change the least amount possible on the design so as to retain the basics that we knew already flew well. If we proposed a change, we had to have good reason to believe that the changes would improve on, and not decrease, the overall handling of the vehicle. This can get tricky, as we also have the goal to get quickly into production. 

The wings will still swing in, maintaining the design that gives the Switchblade its name. While our vehicle as viewed from the top down is almost identical to the prototype that flew, we have made improvements that we feel will not only reduce maintenance and assembly times, but also provide for better performance and lighter weight. We are not done by any stretch of the imagination, but we are very well along with the production design and will be going back to the wind tunnel soon to validate our proposed changes.

I am not showing images at this time as we may file for a patent on one or more aspects of the modifications, but I do believe you will be impressed with not only the performance but the improvement in looks that are shaping up! The goal is to bring landing speeds close to Part 23 Certified standards (Airworthiness Standards for smaller aircraft), which is 61 knots or 70 mph. Our secondary goal is to increase useful load to over 650 lbs. Useful load includes people, bags, and fuel. We are looking to increase the maximum fuel load to be 44 gallons (up from 33 gallons earlier). Pilots will always have a trade-off of range (fuel) versus weight to carry in people and bags. By increasing the maximum fuel capacity, we give pilots more options on scheduling their trips. 

Wind Tunnel Plans

We have just begun engineering and working out the fabrication of the parts that would be changed from our previous wind tunnel model. A lot has improved since we did our earlier work in the Kirsten wind tunnel at the University of Washington, Seattle. 3D printing has changed how one-off parts can be made and has allowed us to engineer faster ways of testing many different wing and control surface layouts. For instance, we previously had to carve out aluminum elevators (moves the nose up or down) for the tail and unbolt them from the basic tail structure to adjust for the next flight test.

In this case, we can 3D print different tail sections with the elevator integral to the part, and just slide them on and off a base metal structure that remains constant. Using advanced techniques, by building a base body structure, we can plug and play different shapes for different sections of the model and test in a way never before imagined. We aren’t the first to utilize such techniques, but we will be using state-of-the-art techniques for our next wind tunnel tests, that is for sure!

The Reason We Are Winning

Samson has developed a Team that has shown a willingness to persevere and overcome any and all challenges along the way to get the world’s most popular flying car into production.

We haven’t always nailed things the first time out, but we don’t give up. The ability to swivel when needed, but still keep the promises of the vehicle intact, is an incredibly valuable asset we provide. This is why we are winning in this new field of transportation.

It is our commitment to you, and all future flying car owners, that we will make this possible. That it remains within financial grasp. That ordinary people can be trained to safely use this kind of vehicle. That the world can be improved as a result of people being able to move more easily, quickly, and with less stress than we have had in the past.

This is the Jetsons Meets James Bond
And Investors Are Welcome

Samson has opened a new Regulation D 506 (c) Bridge Funding round for Accredited Investors. There are a limited number of shares available at the pricing of this round, and if you are an Accredited Investor you may inquire for more details at: samsonsky.com/investors

A definition of an Accredited Investor can be found at:  Accredited Investor Definition

So, whether you are an original Jetson or a unique James Bond, the world awaits. Your high-performance flying car is ready. It is time to start a new and better chapter in humanity. 

When you thought it couldn’t get any better:

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This new video is our best ever!!!

See what all the excitement is all about regarding the world’s first flying sports car

We hope you will share this newsletter with anyone you think would be interested!

Sam Bousfield
Captain, Switchblade Team

Switchblade, Samson Sky, Skybrid, and Skybrid Technology are trademarks or registered marks, and are used with permission on these pages.

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