Olsen Actuators & Drives required static and finite element analysis of a modified COTS actuator to support certification and transition to manufacture for a prototype eVTOL application, under demanding programme timescales.

KDC Projects operated as a fixed-price delivery partner, reviewing the baseline design, undertaking detailed stress analysis and developing an optimised reduced-weight configuration with full compliance evidence.

This enabled CDR approval, supported manufacturing release, and provided validated analytical correlation against subsequent destructive test results.

Requirement

Analysis required for modified COTS actuator to enable certification and manufacture 

Skills & Tools

• Static & Finite Element Analysis using Hyperworks / Optistruct software 

Tasking

Review existing design and conduct analysis to enable product optimisation 

Produce optimised design proposal and rerun analysis to ensure compliance against requirements 

Deliverables

Reduced weight design proposal and stress report detailing all analysis undertaken to support certification 

Outcome

CDR passed and manufacturing standard in line with challenging end customer timescales 

Subsequent destructive testing showed analysis results correlated almost exactly to test results