Visitors to the AERALIS stand at DIMDEX in Doha in March were able to get up close to a full-scale model of the AERSYSTEM Common Core Fuselage (CCF). We caught up with Kane Marshall, AERALIS Assembly Director, to get some insights on the build project.

What was your role in producing the model?

“I oversaw the project from start to finish – that is to say, from selecting our manufacturing partner, EDM, through to the logistics of getting the model safely to Doha in time for the show.”

It’s a hugely impactful way of introducing the AERALIS proposition, not only to defence stakeholders but also for young and future generations of aerospace engineers.”

Kane Marshall, Assembly Director

Why was the model commissioned?

“Firstly, when demonstrating a wholly new concept – and I mean not just a new aircraft, but a modular aircraft system – nothing comes close to the immediacy you get from being able to get up close to, and sit inside, a physical representation.

“Secondly, the last time we produced full scale replicas of the aircraft, the design was very different. That was two years ago for the 2022 DIMDEX show. In less than 18 months, enabled by digital engineering, we made significant changes to the aircraft design, improving performance and module interchange. It was important that we showed the progress and maturity of our engineering, and the model played an important part in telling that story.”

Is the model an exact replica of Phoenix – the first flight test aircraft?

“The model is accurate in terms of what we call the Outer Mold Line – the outer shape of the aircraft. Structural elements of the concept, including the ‘ladderback’, engine seal-plate and wingbox are also accurate, which is significant because of course, they are instrumental in enabling the modular concept; they are the key interfaces between the CCF and aft modules, including empennage, engine and nacelles.”

And the underlying structure?

“Time constraints prevented us from being as detailed as we would have liked, the design and engineering of the CCF is very mature and we would have liked to demonstrate more. But we had to focus on what would deliver maximum impact in the time available.”

How about the construction – was that similar to how Phoenix will be built?

“In many respects, yes. The first models were produced in carbon fibre. This time it’s an all-metal construction with outer panels fabricated in the same way as they would be for the real thing.

And how was the model received?

“It was the centrepiece of our stand at DIMDEX. It helped to transcend language barriers and attracted and engaged visitors from around the world to learn more about the AERALIS programme. Guests could take a seat in the cockpit and really get a sense of how far AERALIS has come in delivering our unique concept.”

Will people in the UK get to see the model at some point?

“We certainly hope so. It’s currently making its way back from Qatar to take up residence at our HQ in Bristol, but we hope we will be able to exhibit it at some point in the UK. It’s a hugely impactful way of introducing the AERALIS proposition, not only to defence stakeholders but also for young and future generations of aerospace engineers.”