Nose

For the construction of the nose section, we employed a design approach consistent with the rest of the aircraft but adapted to meet the nose's unique aerodynamic and structural characteristics. Unlike the tail and fuselage, the nose was developed entirely through digital modeling and fabricated using 3D printing. We began by creating a detailed 3D model in SolidWorks, which allowed us to define precise dimensions, contours, and internal features while ensuring compatibility with the rest of the airframe. This digital environment enabled iterative design improvements and accurate simulation of how the nose would interface with adjacent components.

Once the model was finalized, we prepared the geometry for additive manufacturing. The nose was segmented into printable sections to accommodate the printer’s size constraints and to allow for easier post-processing. Each part was printed using high-resolution settings to maintain the aerodynamic shape and structural accuracy as defined in the SolidWorks model. This method ensured consistent wall thicknesses, smooth surface finishes, and high dimensional fidelity—key factors for a component with such a prominent aerodynamic role.

After printing, we performed a dry fit to verify that each segment aligned correctly and matched the design specifications. Minor surface refinements were carried out where necessary to ensure a seamless assembly. The modular parts were then bonded together, forming a rigid and aerodynamically clean nose structure. This digitally-driven workflow, from CAD modeling to 3D printing, allowed us to produce a highly accurate and lightweight nose section that aligned with real-world aerospace manufacturing practices while reducing manual labor and fabrication errors.