2026 ASEE Annual Conference & Exposition

In an introductory mechanical engineering course, students are often eager for hands-on projects that connect fundamental concepts to tangible design challenges. This paper presents a two-lab sequence developed to integrate design of experiments (DOE), optimization, and aerodynamics using balsa wood glider wings fabricated in the campus maker space.

The sequence begins with students completing maker space safety certification, enabling them to laser-cut trapezoidal wings. In the first lab, students conduct a three-factor full factorial design of experiment, systematically varying geometric parameters of the wing to investigate their impact on flight range. Using the data collected, students analyze the results and identify an optimized wing design.

In the second lab, students extend their optimized design to explore the relationship between aerodynamic forces, stability, and weight distribution of stored cargo. Using a graphical method, they determine the center of lift of their wing, then experimentally adjust the cargo's weight distribution/location to align the center of mass beneath the center of lift, thus eliminating destabilizing moments. This exercise reinforces concepts of lift, balance, and moment arms, demonstrating how stable flight is achieved and how poor alignment can lead to stalling or crashes. The sequence culminates in a small competition where students test the range and stability of their gliders, adding a motivating and playful dimension to the experience.
Overall, the lab sequence provides first-year students with an engaging introduction to experimentation, optimization, and aerodynamics while building teamwork, problem-solving, and prototyping skills. It highlights the value of integrating fabrication tools into engineering education to foster creativity and experiential learning. The paper provides packaged lab assignments.