A group of five HNC Aeronautical Engineering students undertook an exciting project that challenged them to think and work like aerospace engineers. Their task was to investigate how different aircraft wing shapes, known as aerofoils, affect aerodynamic performance.
The project began with the students researching industry-standard NACA aerofoil designs, which have influenced aircraft wing development for decades. Using CAD software, they transformed these aerodynamic profiles into digital 3D models before manufacturing them using FDM 3D printers and PETG material.
Once the aerofoils had been produced, the students tested them in a wind tunnel to examine how they performed under different flight conditions. By changing the angle of the aerofoil relative to the airflow, they were able to observe how lift and drag forces changed, replicating the aerodynamic behaviour experienced by aircraft during take-off, cruise and landing.
Using data collected during the experiments, the students analysed the performance of each aerofoil and compared the results with aerodynamic theory. This allowed them to identify which designs generated the most efficient balance between lift and drag, demonstrating the importance of wing design in aircraft performance and fuel efficiency.
The project provided students with valuable experience across the full engineering process, from research and design through to manufacturing, testing and data analysis. It also highlighted the critical role that wind tunnel testing continues to play in the aerospace industry, helping engineers evaluate new designs before they ever take to the skies.
By combining modern design tools, additive manufacturing and practical experimentation, the project gave students a real insight into how aircraft are developed and reinforced the strong link between classroom learning and real-world engineering practice.
Interested in our Level 4 and Level 5 Aeronautical Engineering or Space Technologies courses? Learn more on our website here.
