Background & Goals

As part of the structural engineering team for the Piaggio P180 Avanti aircraft, I was responsible for developing detailed 3D models for the primary carbon fibre structure. The goal was to produce an efficient and lightweight airframe while ensuring manufacturability and structural integrity in line with aerospace standards.

Design & Development

Working in CATIA V5 and in close collaboration with the stress engineering team, I iteratively refined composite part geometries based on FEA load simulations and manufacturing constraints. My focus was on ensuring the accuracy of laminate definitions, ply drop-offs, and core reinforcements. Outputs included the full 3D data set and manufacturing drawings required for CFRP production (drawings, models, playbooks and tooling).

Results & Feedback

The final design met all structural performance requirements and passed simulation-based validation. Our efficient workflow between design and stress teams helped reduce design iterations and enabled early release of production data, supporting faster prototyping. The accuracy of the model contributed to a smoother handoff to manufacturing.

Final Thoughts

This project highlighted the importance of tight integration between design and analysis teams, and deepened my appreciation for the precision and discipline required in aerospace composite design. It also reinforced my belief that engineering elegance lies in clarity, communication, and clean execution.