This stunning flow visibility technique allows us to catch the flow of air separation in low pressure areas. We’re looking for ‘separation’ which wouldn’t occur in a high pressure area like the forward portion of the nose.

In case you missed any of the newsletters in recent months, I wanted to summarize here:
We have been working on production engineering for the Switchblade and were tweaking the design to get the improvements needed for production vehicles. After First Flight of the prototype last November (which went spectacularly by the way) we finalized a handful of important improvements to be made before we go into production. A key area to improve was our speed targets – and after much investigation found that we would not be able to do so with the single large ducted fan in the rear. We worked quickly to get an alternate method of propulsion, which we accomplished, and added in the rest of the improvements we had slated for production vehicles. I can tell you, the updates to the design and engineering are exciting!

These updates greatly reduced the drag and improved thrust efficiency to the point where we felt we had a design that we could take to the market. We are applying proven propulsor methods to solve the thrust/drag issues we found with our flying prototype. Those many aspects of the Switchblade that were proven to work well during flight testing have been kept, and the Switchblade today looks almost identical to the Switchblade that flew. Past newsletters have shown that work, so if you haven’t read past newsletters, please check those out. We’re adding an “Latest Updates” section to our website in the coming weeks with all past newsletter updates so you can always check in on what’s happening in the Samson Sky world.

Wind Tunnel Confirms Design Improvements

The last newsletter talked about the upcoming wind tunnel testing, and that we were using 3D printed parts to get into the wind tunnel faster. This worked out just as planned and on schedule, but not without extra time spent by the Samson Team to ensure that it did! Our Team did an incredible job getting the work done on time for our weeklong scheduled slot in the Kirsten Wind Tunnel in Seattle, Washington. The Test Team included Ronald Forseth,Tanner Vaughn, Dana Beebe, David Nobles, Sam Bousfield, and consultant aero engineers Bryan Sandoz and Mike Cavanaugh. We also had some help from both Risse Racing and Tilker Machine & Design of Redmond, Oregon, who provided the machining services for the wind tunnel model to meet our deadline.

As some background to the wind tunnel, aero design is first done by sketching, then hand calculation and computer simulation. Computer simulation has advanced greatly and can typically get you within 10% of actual. To really validate a design, you need to go to the wind tunnel as that gets you within 3% of actual. This is what we just accomplished.

We started by shipping all of the parts up to Seattle and installing the model into the wind tunnel. The body and wings were shipped pre-assembled and we bolted up the tail once we had the model in the tunnel. The model is still fairly heavy as it is large (1/4 the size of the Switchblade), so we used the hoist at the tunnel to lift the body and wing combo portion up from the ground receiving area to the second story wind tunnel model room.

You can see this in the image below which is looking up at the model (which is sitting in its crate) from the receiving area below the wind tunnel. The model is being lifted above the wind tunnel prior to being shifted sideways and then down into the tunnel. The metal wings are covered in blue and green painter’s tape to protect the surfaces during transit. You will notice that the wings are swept backwards more than the original design. This was done to move the aircraft center of lift rearwards to preserve the good lift-off qualities we found in flight testing last fall.

So What Did We Learn?

We found that the wing design is working just as planned and we also chose the best flap style for our needs. We tested three different flap styles (flaps are the movable parts of the main wing closest to the body that slow an aircraft down for landing and make the wing seem bigger at the same time). One style gave the best performance with the least mechanical challenges and was the original style of flap that was used in our prototype that flew last fall. So, our flap system has been decided, and the wing size and shape is validated.

The ailerons are the movable surfaces on the wings that bank the aircraft left or right for turns, and we found that the ailerons were a bit larger than we needed, and we may reduce the aileron size to reduce drag. Drag is the friction of moving through air (what you feel when you stick your hand out the window of a moving car). Removing drag allows us to fly with less fuel burn and lowers the required horsepower.

Reduced Drag Explored and Validated

We mocked up different shapes on the body to generate the least drag and found the one that provided the least drag and provided two more benefits at the same time including more stability for the vehicle in the air. It is nice to get a two for one deal, but this was a three for one deal! Even better!

One way we determined this was to use Flow Visibility techniques. There is a special material that is painted (more like poured) onto the wind tunnel model, and then the wind is turned on. The lights to the tunnel are turned off and blacklights are used to see the material flow as it hardens in the wind. Once the material has stopped moving, the wind is turned off and the model examined. You can see in the image below that the air streaming past the nose along the sides of the vehicle is nice and smooth. This was the case for most of the model.

We can’t show all of the model yet, as we are still working on what we might patent regarding the improvements made. Once we have the outer shape fixed and our patents filed, we will make a public unveiling of this, which we think will blow your mind!

3D Printed Parts for 1/4 Scale Wind Tunnel Model Performed!

The Samson Team used 3D printing to make most of the wind tunnel model. There was an internal aluminum and steel structure for mounting the wind tunnel model, and the tail boom and non-movable portion of wing and tail were made of aluminum. The rest of the model was 3D printed structural plastic (PTEG). This really sped up the process for making the over 60 parts used in the tests.

The printed parts held up just fine and were easy to swap out from test to test as we ran through the planned series of wind tunnel runs. Each test is logged, photographed, calculated based on the raw data, and graphed. With this many tests, we haven’t been able to go through everything yet, but the main points were clear: WE HAD SUCCESS! The image below shows one of the 3D printed parts being mounted on the wing of the Switchblade test model in the wind tunnel by Samson Lead Engineer, David Nobles.

Legislative Success!

Samson has been involved in helping new legislation be written and passed in several states. The first was in New Hampshire several years ago. Just recently Minnesota became the second state in the US to create a simple and clear path towards registration of flying cars. The Governor of Minnesota, Tim Waltz, signed a transportation bill enabling simplified flying car registration. This was a broadly supported bill and it was nice to see the effectiveness of their state legislature in getting new and helpful legislation passed. Kudos to the State for being pro-active and supportive of new technology. Samson’s Government Relations Director Russell Bousfield is commended for supporting and encouraging legislators from multiple states who are working on similar bills.

Reservations and Deposits

We want to clarify that there are still two ways to Reserve a Switchblade.

Option A): Become a Depositor

Reserve with a $500 non-refundable deposit. Depositors will receive a fixed Delivery Position. They will receive their Welcome Pack as a confirmed Depositor for their Switchblade. They are also invited to take part in the design of the Switchblade by participating in our Depositor surveys, and can purchase Switchblade Gear at a discount.

Option B): Become a Reservation Holder

Reserve with no money down. Reservation Holders receive their place in line. A reservation gives them a place in line relative to other Reservation Holders. The Reservation option with no money down has no commitment and no funding required at this point. When ready to buy, they would place their Deposit, become a Depositor and then would receive their fixed Delivery Position.

So, to recap:
Depositor = fixed Delivery Position ahead of Reservation Holders
Reservation Holder = place in line relative to other Reservation Holders

Please note: All funds are credited towards your future purchase of a Switchblade kit that includes the Builder Assist program. Making your deposit does not obligate you to buy, should circumstances change. The Depositor has claimed a fixed Delivery Position ahead of all Reservation Holders. This also gives Depositors the easiest and least expensive way to gain an earlier Delivery Position.

Investment Opportunity Opened for Accredited Investors Only

Samson has opened our first major fundraising for large investment to get the Switchblade into production. This is called a Reg D Series A (first major fundraise), and we are VERY pleased with the response and interest. This particular investment is reserved for Accredited Investors only due to the large dollars being sought. If you ever wondered whether you qualified as an Accredited Investor, you can check out the requirements here:
What Is An Accredited Investor? – Forbes Advisor

To learn more about this opportunity, please use the Investor Inquiry form on the website:
https://www.samsonsky.com/investors/ 

Want to re-watch our most popular video? Here it is:

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

Sam Bousfield
Captain, Switchblade Team