I conducted trade studies on airbrake designs and actuation methods, evaluating weight, reliability, and overall performance, which led to the selection of a spiral cam-driven lateral flap airbrake design. Using first-principles analysis, I approximated worst-case flight loads and sized components to minimize
weight while maintaining sufficient strength. I then used finite element analysis to validate critical stress calculations performed by hand. Applying design for manufacturing and assembly principles, I designed key mechanical components in SolidWorks with their intended manufacturing processes and tolerances in mind, including CNC machining, FDM printing, composite layups, and waterjet cutting.