Scout helicopter
Design a light experimental helicopter for accessible flight
Brand background
Horizont design bureau provided a history of their helicopters, the feelings they want to evoke and some fundamental constraints (such as a maximum weight).
A flying visit
Visited the Horizont design bureau to see a current production model.
Sketching
A few rounds of initial idea sketches
Initial proposal rotatiton
“it’s all wrong. you got the task wrong, there is too much of automotive style here. it has to be about adventure, not limos.”
Switch theme, adventure
Face adventure
Sketch work showing work that encompassed a new plastic nose that cuts the silhouette and makes the helicopter look more adventurous.
In flight renders
Presentation sketch of the helicopter in situé, drawn over cad models provided by horizont to keep things fast and fresh.
A nose job
Anyone who's designed a vehicle of any kind knows how important the face and expression of it is. With a helicopter, the nose and its shape are of paramount importance.
Design refinement
Design refinement
Design refinement
Multiple prototypes from manufacturers used to refine the design up to a pre-production model (shown here)
We worked closely with horizont to define the split lines and part cuts.
We worked closely with horizont to define the split lines and part cuts.
High beams
The main beams remained a point of contention, in the end, three CAD renders were presented before the middle design (in green) was chosen by Horizont.
C.A.D refinements
A series of CAD models were sent to the client so they could discuss widely internally if they we're happy with the direction and sure the new tooling for bodywork wouldn't cost too much.
A handle on things
To reduce costs and the number of tools and manufacturing required for parts involved we suggested using readymade car door locking mechanisms for the door handles.
Full-size foam
The CAD model was then use to create a full-size foam model of the bodywork, to fully understand the form in 3D space.
Aero-optimisation
After simulating turbulence and flight pressures the aerodynamics of the design were found unsuitable, the truncated flat nose would result in instability when flying, the red lines above show how the form was tweaked.
Model 2
The new aerodynamically stable design was then made into a scale model, at this point we were able to define where the part split lines should be.
Splitting up
Further definition of the split lines, to be folded back into the CAD model.
Resurfacing
The surface model had to be reworked at the top to ensure it didn't intersect with the rotor mechanism.
Door lock redesign
The door locking mechanism had to be repositioned to the base of the door which meant the mechanism previously proposed (using pre-made components) wasn't suitable, a range of mechanisms/designs were sketched out.
Colours
We explored a range of colour options and themes before settling with the client on a customisable framework.
Exhibition sample
The first to scale sample unit was shown at a sales exhibition to judge consumer interest and build buzz.
Scout takes flight
With a proof of concept model with all the mechanics in place built, things really took off.
(with love)
