From Concept to Full-Scale Development

Work on the Aerolite Spitfire began in 2015 with a series of concept drawings that evolved as the design developed.

An early priority was the construction of a full-scale fuselage mock-up as a practical design aid. CAD modelling and 3D printing were used extensively to establish the aircraft’s overall dimensions, proportions, structural arrangement and cockpit geometry.

A full-scale model provides something that computer modelling alone cannot: the opportunity to evaluate the aircraft physically.

It allows designers to assess ergonomics, component integration, structural concepts, accessibility and the relationship between the pilot and the aircraft before committing to the final design.

Two further full-scale cockpit mock-ups were subsequently produced for detailed comparison: one reproducing the original Spitfire’s single-seat cockpit and the other representing the Aerolite’s tandem configuration.

These were used to evaluate pilot seating position, control accessibility, instrument-panel layout, cockpit dimensions, field of view from each seat and overall crew comfort.

This progressive, full-scale development process allowed the design to evolve around the people who would eventually fly the aircraft, rather than requiring the pilots to adapt to a predetermined layout.