Wednesday, October 29, 2025

Aerodynamics of the NASA QueSST X-59 Quiet Supersonic Transport

X-59 Quiet Supersonic Transport Study Using Stallion 3D

I ran a new quiet-supersonic study at Mach 1.45 and 55,000 ft using the built-in atmosphere tables and Cartesian solver in Stallion 3D. The goal was to reproduce and understand the kind of pressure distribution seen in the NASA X-59 QueSST demonstrator, which recently completed its first flight. The idea is the same: manage the shock pattern so the ground hears a soft “thump” instead of a sonic boom.

Shock Management Along the Nose

The simulation shows a controlled series of small compressions marching down the forebody rather than one big, coalesced shock. That’s exactly what quiet-supersonic shaping is about—spreading the pressure rise (Ξ”p/Ξ”x) gradually so the far-field signature becomes a sequence of gentle steps instead of a single N-wave.

At these flight conditions, the distributed shock train is similar to what the X-59 team reported during their low-boom configuration tests. It’s encouraging to see Stallion 3D’s Navier–Stokes solver naturally produce the same kind of flow behavior on a simple Cartesian grid.

Canopy and Inlet Shoulder Interaction

Right behind the cockpit, a red-blue compression and expansion pattern forms where the fuselage grows into the wing root. This region is a classic challenge in supersonic design—where cross-section growth and lifting surfaces meet, shocks can thicken and contribute to secondary noise.

It’s good to see that Stallion 3D’s refinement zone resolves these local gradients clearly, without any hand-built body-fitted grid. The automatic cell concentration gives an accurate look at how geometry transitions affect both drag and acoustic signature.

Aft-Body and Tail Effects

The aft wing and tail surfaces are doing real aerodynamic work. The pressure remains mostly clean, but there are still distinct compression and expansion regions being shed downstream.

In low-boom design, the rear shaping is as important as the nose. The aft body determines how the pressure signature closes—the part that controls how the sonic waveform ends. That’s the part that often separates a “thump” from a “bang.”

Refinement Zone and Solver Performance

The local grid density around the aircraft shows that the refinement box is working exactly as intended. It captures oblique shocks and shear layers efficiently, even at Mach 1.45, without requiring a fitted mesh.

From a numerical standpoint, this confirms that Stallion 3D’s Cartesian method is practical for supersonic concept studies—especially for early X-59-style configurations or general quiet supersonic transport layouts.

Realistic Flight Condition

The run used true high-altitude conditions (55,000 ft, Mach 1.45) from the built-in atmosphere model. These are the same conditions typically quoted for quiet-supersonic cruise tests and community response research under NASA’s QueSST program.

That realism matters for both acoustics and aerodynamics. At these pressures and densities, thin, swept lifting surfaces behave differently than they do in low-altitude transonic tests.

Next Steps

  • Extract the far-field pressure trace along the ground track (Ξ”p vs. time) to evaluate perceived loudness.
  • Quantify lift, drag, and moment coefficients (CL, CD, CM) to separate wave drag from viscous effects.
  • Run sensitivity tests by shortening the nose or modifying canopy cross-section to see how it reshapes the shock train.

Conclusion

This quiet-supersonic run demonstrates what Stallion 3D does best—showing real aerodynamic detail from first principles without external meshing or post-processors. The solver’s ability to capture distributed shocks, canopy interactions, and aft-body effects all in one pass makes it an effective tool for early design of low-boom aircraft like the X-59 QueSST.

It’s not about pretty colors; it’s about credible data at real flight conditions. The results show a clean, believable Mach 1.45 solution with controlled shock structure—the kind of solution that points the way toward practical, certifiable overland supersonic transport.

Learn more ➡️

Please visit https://www.hanleyinnovations.com for more information.

Friday, October 24, 2025

Multi-element Airfoils analysis with arbitrary shapes: Learn more about the best airfoils tools

Do Fish Swim Like Multi-Element Airfoils?

In nature, a school of fish moves as a coordinated system. Each fish swims in the wake of another, taking advantage of pressure differences and induced flows that reduce drag and save energy. It’s a clean example of fluid mechanics at work — and not too different from how engineers design multi-element airfoils for high lift.

The image above shows a simulation created from fish-shaped outlines. The shapes were first traced as simple drawings and then captured using Airfoil Digitizer. Airfoil Digitizer lets you turn almost any outline — hand-drawn, scanned, or imported — into an analysis-ready shape. You are not limited to NACA airfoils or standard sections. If you can sketch it, you can analyze it.

After digitizing the shapes, I placed them together and ran a potential flow solution in MultiElement Airfoils. This solver computes the velocity and pressure field around multiple bodies at once, and shows how they interact. The colored contours represent pressure: blue for low (suction) regions and red for higher pressure. You can see how each “fish airfoil” changes the flow around its neighbors, very much like the interaction between a slat, a main wing, and a flap.

This is the interesting part: even with playful shapes, the physics is still there. You get wake shielding, suction peaks, and local acceleration in the gaps. That’s the same family of effects we care about in real applications — multi-element wings, hydrofoils, propeller/wing interference, and UAV control surfaces working close together.

The workflow here was:
1) Sketch or outline a shape
2) Capture it with Airfoil Digitizer
3) Arrange multiple elements and solve the flow in MultiElement Airfoils
4) Visualize pressure and interaction

It’s a fun demonstration, but also a serious one. Airfoil Digitizer gives you full control over the geometry. MultiElement Airfoils lets you study how multiple lifting surfaces behave together, not just one at a time. Together they make it easy to explore ideas, test concepts, and see the aerodynamics before you ever build a model.

Visit ➡️ https://www.hanleyinnovations.com

Best regards,
Patrick

Thursday, September 25, 2025

CFD and Aerodynamics of a Blown Wing for eSTOL, STOL & eVTOL Aircraft Design and Analysis



This guide condenses the video transcript into a short, actionable tutorial. Follow the steps below to replicate the workflow shown in the video.  Applications include eSTOL, STOL and eVTOL aircraft.

Tutorial Steps (from Transcript)
  1. Hello and welcome to Hanley Innovations. Today we will outline how to set up actuator discs in Stallion 3D to implement a blown wing concept.
  2. First, we create the wing in Stallion 3D using the built-in geometry tools. This wing has a span dimension of 4 m and a cord of 1 meter.
  3. It uses a NACA 4412 from the built-in library. Next, we enter the actuator discs parameters.
  4. For all four, we set a force of 500 Newtons. We copy the first disc and set the Y center to minus 0.75.
  5. Next, with the same copy, paste a discs with Y centers of 0.25 and minus0.25 respectively to complete the propulsion distribution. Next, set up the CFD using 1 million cubes with the initial X, Y, and Z settings of 2, 2 and two.
  6. Use the default Navier Stokes solver. Then click the generate grid solve flow menu.
  7. Stallion 3D will automatically generate the grid and solve the flow. The results show the effects of the disc's prop wash over the wing and in the wake.
  8. We can now compare the lift force of the unpowered wing to that of the blown wing. The unpowered wing has a lift force of 24 lb in the 20 m/s flow field.
  9. The blown wing has a lift of 70.8 lb. 
  10. Until next time, thanks for watching.

 For more information, please visit https://www.hanleyinnovations.com

Wednesday, September 10, 2025

Quick and Accurate UAV Aerodynamics Analysis using Stallion 3D

Solved by Default πŸ› ️ — Import • Mesh • Solve in Stallion 3D

A quick walkthrough by Dr. Patrick Hanley (Hanley Innovations)

Watch: Solved by Default — Stallion 3D

Click the image to watch the short demo on YouTube.

In this quick demo, we import a drone STL, let Stallion 3D auto‑configure the CFD boundaries and domain sizing, pick a sensible default mesh, and run the solver—going from geometry to pressure contours in minutes.

What the video covers

  1. Import geometry via Design → Import STL (ASCII or binary). Set units (e.g., meters) and position/orientation.
  2. Automatic domain & boundaries: Stallion 3D sizes the CFD box and boundary conditions from the STL—so you don’t have to hand‑tune the grid extents.
  3. Optional geometry quality check: If your STL has gaps/holes, run the quick check to mitigate issues before grid generation.
  4. CFD setup with smart defaults: choose a mesh density (Quick, Medium, Large; example shown: ~1 M cells). The default solver and domain dimensions are good starting points.
  5. Generate & solve: Start meshing and the flow solution in one click.
  6. Visualize results: View the 3D geometry and pressure distribution; add legends/units (Pascals) with the graph options.

Why this workflow is fast

  • No manual domain sizing—it’s solved by default.
  • Defaults that “just work” for early design checks.
  • Applies across subsonic, transonic, and supersonic regimes for rapid concept iteration.
Watch the short demo

Prefer reading? Reply with questions—happy to help you try this on your geometry.

© Hanley Innovations • This email is informational. Video & demo: Dr. Patrick Hanley.

Friday, August 22, 2025

What Is a Multi-Element Airfoil? Aircraft, Cars & Design Explained


What Is a Multi-Element Airfoil?

How they work for aircraft takeoff/landing, motorsports downforce, 

and how they are designed by engineers.

Quick definition

A multi-element airfoil is a lifting surface made from two or more cooperating profiles—typically a main element plus leading-edge slats and/or trailing-edge flaps. By carefully positioning the elements (gaps, overlaps, and deflections), designers dramatically increase lift (for aircraft) or downforce (for cars) at low to moderate speeds without making the wing excessively large.

Why multi-element airfoils work

  • Circulation & camber boost: Slats and flaps increase effective camber, strengthening circulation and lift.
  • Slot effect (boundary-layer control): The gap between elements jets high-energy air over the next element, delaying separation and letting the system reach higher lift coefficients before stalling.
  • Fowler motion: Many flaps translate rearward and rotate, increasing wing area and camber simultaneously.
  • Load sharing: Each element carries part of the pressure jump, reducing peak adverse gradients on any single surface.

In practice, a single-element airfoil might achieve a CL,max around ~1.4 (order of magnitude), while a well-designed multi-element system can exceed ~2.5–3.0+ depending on geometry, Reynolds number, and deflection schedule. (For cars, think of “negative lift” or downforce rather than positive lift.)

Where you see them in the real world

Jet airliners (takeoff & landing)

Airliners need huge lift at low speeds to operate from practical runways. On approach and takeoff, they deploy leading-edge slats and multi-segment trailing-edge flaps to raise CL,max, allowing lower approach speeds, shorter distances, and improved safety margins. In cruise, devices retract to reduce drag.

Business jets, turboprops, and STOL aircraft

Many business jets and turboprops use slats and flaps for field performance. Short-takeoff-and-landing (STOL) aircraft do the same, sometimes adding devices like fences, cuffs, Krueger flaps, or blown flaps to energize flow and improve controllability near stall.

Uncrewed aircraft & model aviation

UAVs benefit from high-lift systems for heavier payloads or shorter fields. Multi-element tails or deployable flaps are common on fixed-wing drones that must launch and recover in tight spaces.

Motorsports & performance cars

Racing wings often use two or more elements (plus Gurney flaps) to produce large downforce at modest speeds, improving grip in braking and cornering. Rules usually cap element count and geometry, so careful design of slot gap, overlap, and flap angle is crucial to hit the aero targets without stalling the wing.

Key design choices

  • Architecture: How many elements? Slat + single flap, double-slotted flap, or more?
  • Gap & overlap: Tiny changes (millimeters) in the slot can make or break high-lift performance.
  • Deflection schedule: Angle and translation vs. speed/phase (takeoff vs. landing) or, for cars, vs. ride height/attitude.
  • Reynolds/Mach effects: Section choice and flap geometry depend on size and speed regime.
  • 3D integration: Wing twist, endplates/fences, tip effects, and flap track fairings all matter.
  • Structures & mechanisms: Added complexity, weight, and maintenance vs. performance gains.
  • Noise & certification: For aircraft, aero-acoustic considerations can drive geometry and schedules.

A practical workflow for designing multi-element airfoils

  1. Define the mission: Field length, stall margins, approach/takeoff speeds (aircraft), or target downforce/drag window (cars).
  2. Choose a baseline section: Start with a main element suited to the Reynolds number and thickness needs.
  3. Select devices: Slat type and size; flap type (plain, split, single-slotted, double-slotted, or Fowler); Gurney height.
  4. Set initial geometry: Gap/overlap and hinge lines; add mechanical constraints for real deployable hardware.
  5. Analyze 2D performance: Sweep angles of attack and device deflections to map CL, CD, Cm, and stall behavior.
  6. Scale to 3D wing/car installation: Include spanwise effects, endplates/fences, and local ground effect (cars).
  7. Optimize the schedule: Create “takeoff” and “landing” (or “low-speed” and “high-speed”) settings; validate against constraints.
  8. Iterate with CFD and tests: Refine details such as slot curvature, fairings, and sealing strategies.

Design faster with Hanley Innovations software

Hanley Innovations provides tools that streamline multi-element airfoil and wing design—from early concepts to practical, test-ready geometries:

  • MultiElement Airfoils – Rapidly configure slats, flaps, gaps, and overlaps; evaluate high-lift performance across deflection schedules. Ideal for airliner high-lift studies, STOL concepts, UAVs, and motorsports wings.
  • 3DFoil – Analyze full wings and tail combinations quickly, explore stability derivatives, and build trim maps that incorporate your high-lift settings.
  • Stallion 3D – Move to full-3D CFD when you need richer flowfield details (pressures, forces/moments, and flow features) on real geometries, including multi-element systems and car wings.

Ready to accelerate your high-lift or downforce project?

Visit Hanley Innovations to explore MultiElement Airfoils, 3DFoil, and Stallion 3D.

FAQ

How many elements are “too many”?
Diminishing returns set in as mechanical complexity, drag, and sensitivity increase. Most practical systems use one slat and one or two flap elements; motorsports rules often limit element count explicitly.

Do Gurney flaps count as an element?
They’re typically treated as a device on an element rather than a full element, but they can significantly boost lift/downforce at the right Reynolds numbers.

What’s the most sensitive parameter?
The slot (gap and overlap) and the deflection schedule. Small tweaks here can change peak performance and stall character.

© Hanley Innovations • Tools and methods here are for educational guidance; always validate with appropriate analysis and testing for your application.

Sunday, August 10, 2025

Rocket Aerodynamics Video Tutorial

πŸš€ Rocket Aerodynamics — From STL to Flight-Ready Insights

Altitude is great—but control and stability win flights. In this video, I show how to take your rocket’s STL file and run a complete CFD analysis in Stallion 3D so you can predict side force, spin tendency, and CP shift before launch.

What’s inside

  • Import your STL from OpenVSP, Tinkercad, or OpenRocket
  • Set realistic flight conditions: Mach, altitude, angle of attack
  • Run the solver to get surface pressure, side force, yaw moment, spin tendency, and CP shift

Why it matters

Estimates for CG/CP are a start, but they miss critical effects—fin misalignment, transonic bumps, and asymmetric forces. Stallion 3D gives you the full aerodynamic picture so launches are straighter, faster, and more reliable.

Smarter launches start here. — hanley@hanleyinnovations.com

Wednesday, August 6, 2025

Rocket Aerodynamics with CFD Simulations πŸš€


πŸ› ️ From CAD to CFD in 3 Easy Steps

  1. Export your rocket design as an STL file (from Fusion 360, OpenVSP, OpenRocket, etc.)
  2. Import it directly into Stallion 3D
  3. Simulate full 3D aerodynamics: side force, spin, CP/CG behavior, Mach effects

🎯 Why Use Stallion 3D?

  • ✅ Simulate at any Mach number — from subsonic to transonic and supersonic
  • ✅ Understand yaw-induced spin and asymmetrical loading
  • ✅ Analyze launch stability and fin performance
  • ✅ Works directly with STL files — no mesh cleanup needed

πŸ’‘ Perfect For:

  • πŸ§‘‍πŸ”¬ Engineers building high-power rockets
  • πŸ† Students competing in TARC, Spaceport America Cup, SEDS, and more
  • πŸŽ“ University & high school rocket teams

πŸš€ Ready to launch your next rocket with confidence?

πŸ₯ΌRemember, you don't have to be a rocket scientist to use Stallion 3D.

Learn more: https://www.hanleyinnovations.com

πŸ“§ Contact us for more information:

https://www.hanleyinnovations.com/contactus.html