01 / DIGITAL DESIGN
Digitizing original paper plans and building CAD models of every part.
Overview
Students are building an airplane.
The club received a donation of original Sonex A-Model scratch-build plans, the aluminum sheet to build it, and the original purchase documentation. Students are turning those decades-old paper plans into a modern digital manufacturing workflow, then using it to build the aircraft.
The project follows all applicable FAA, University, safety, insurance, and aircraft-operation requirements.
Build progress
Plans to flight.
- Plans
- Digital Design
- Manufacturing
- Assembly
- Systems Integration
- Inspection
- Flight Testing
- Flight
Why we're building it
Real engineering, start to finish.
Hands-on
Design, manufacturing, and assembly on a real aircraft.
Continuity
A multi-year project each class of students builds on and documents for the next.
Careers
Experience that carries straight into aerospace and manufacturing work.
"We built that."
Something students can point to and say they helped build.
The aircraft
Sonex A-Model
An all-aluminum, two-seat homebuilt aircraft built from legacy scratch-build plans.
| Type | Experimental Light Sport |
|---|---|
| Seats | 2 |
| Construction | 6061-T6 Aluminum |
| Wingspan | 22ft |
| Engine | Various Options |
| Plans | Original scratch-build (donated) |
Workflow
From paper to parts.
02 / MANUFACTURING
CNC machining, waterjet cutting, and sheet-metal fabrication using on-campus and off-campus engineering resources.
03 / ASSEMBLY
Structural assembly, hardware integration, avionics, and systems, with quality control and inspection throughout.
Build log
Project updates
Newest first.
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Plans digitization begins
Our team is converting the paper plans into CAD files for CNC cutting.
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Plans and materials donated
The club received original Sonex A-Model plans, aluminum sheet, and purchase documentation.
Team
Workstreams
CAD & Design
Plan digitization, modeling, drawings.
Manufacturing
CNC, waterjet, sheet metal, tooling.
Assembly
Structures, hardware integration.
Systems & Avionics
Electrical, instruments, engine systems.
Quality & Safety
Inspection, QC, compliance.
Docs & Project Mgmt
Build records, schedule, knowledge transfer.
No experience required. Join the club and pick a workstream, or apply for an open CAD role.
Partners & sponsorship
Help us get it flying.
We're looking for manufacturing support, materials, tooling, technical mentorship, and sponsors.
Your Logo Here
FAQ
Questions
Will it actually fly?
That's the goal. Flight happens only after inspection and every FAA, University, safety, and insurance requirement has been met.
Do I need experience to help?
No. Experienced members train new ones, and every task gets documented.
Where is it being built?
Plans and CAD work are based at our club office, 333 East Campus Mall, Suite 14, Madison, WI, where the original plans are kept. Locations for fabrication and assembly are still being finalized.
How long will it take?
TODO: answer.