Outline

Overview

This unit aims to introduce students to the theory and practice of aircraft component design. In doing so it will emphasise all the considerations, trade-offs and decisions inherent in this process and thus enable students to gain an understanding of why aircraft structures are designed in the way they are with respect to aircraft operational, certification, manufacturing and cost considerations. At the end of this unit students will be able to understand the design process, especially as it applies to aircraft individual component design; Have a familiarity with some of the standard industry practices for component design; An increasing familiarity with typical aerospace analysis techniques along with the primary failure modes that need to be considered; An understanding of the importance of different failure modes for different components and how these relate to load-conditions; a farmilarity with the operating environment that must be considered when designing components; and understanding of some off the legal and ethical requirements of aircraft design engineers to give a basic understanding of the regulatory framework in which aircraft design is conducted.

Unit details and rules

Academic unit	Aerospace, Mechanical and Mechatronic
Credit points	6
Prerequisites ?	AMME9301 and MECH9400
Corequisites ?	None
Prohibitions ?	AERO8460
Assumed knowledge ?	Mathematics, Physics and Solid Mechanics at the level of Bachelor of Engineering, Science or equivalent
Available to study abroad and exchange students	No

Teaching staff

Coordinator	Sydney Dolan, sydney.dolan@sydney.edu.au

Assessment

The census date for this unit availability is 31 August 2026

Details
Criteria

Type	Description	Weight	Due	Length	Use of AI
Written exam	Final Exam Closed Book Final Exam with Limited Access to Hardcopy Support Notes.	35%	Formal exam period	2 hours	AI limited - refer to Canvas
Outcomes assessed:
Out-of-class quiz	Online Quizzes Quizzes based on recent course content	10%	Multiple weeks	N/A	AI allowed
Outcomes assessed:
In-person written or creative task	Mid-semester In-class Test Closed-book test with Limited Access to Hardcopy Support Notes.	15%	Week 06	1 hour	AI limited - refer to Canvas
Outcomes assessed:
In-person practical, skills, or performance task or test	CAD Assessment 1 Demonstrate CAD skills during class	10%	Week 07	1 to 1.5 hours	AI prohibited
Outcomes assessed:
Creative work	CAD Assessment 2 Submitted CAD and drawing files	10%	Week 12 Due date: 30 Oct 2026 at 23:55 Closing date: 30 Oct 2026	N/A	AI allowed
Outcomes assessed:
Creative work	Group Design Assignment Submitted working group report with group contribution table.	8%	Week 12 Due date: 30 Oct 2026 at 23:59 Closing date: 30 Oct 2026	N/A	AI allowed
Outcomes assessed:
Q&A following presentation, submission or placement	Group Projects Discussion Demonstration and explanation of the design process held during tutorial session	12%	Week 13	15 - 25 minutes	AI prohibited
Outcomes assessed:
Evaluation	SPARKPlus for Group Projects Group Contribution Self and Peer Assessments in SPARKPlus.	0%	Week 13 Due date: 06 Nov 2026 at 23:55	30 minutes	AI allowed
Outcomes assessed:
= hurdle task ? = group assignment ? = early feedback task ?

Assessment summary

Group Project (30%): This consists of a truss frame design project and a group CAD assembly project. A penalty per day will be applied for late submission. Standard late penalty applies as outlined in Assessment Procedures 2011.
Online Quizzes (10%): Delivered via the Canvas platform, these self-guided quizzes help you with the knowledge and application of the learning and teaching material. More importantly, these quizzes will help you prepare for the mid-semester test and end-of-semester test. A penalty per day will be applied for late submission. Standard late penalty applies as outlined in Assessment Procedures 2011.
CAD Assignment (10%): The individual Computer Aided Design assignments designed to help you understand the relevant features used to create models and engineering drawings that are applicable to aerospace/aeronautical structures. Standard late penalty applies as outlined in Assessment Procedures 2011.
Mid-semester Test (15%): This will be a closed-book* mid-semester test with limited access to notes and resources.
Final Exam (35%): This will be a closed-book* end of semester test with limited access to notes and resources.
SPARKPlus: SPARKPlus will be used to collect self and peer assessment to both evaluate a team member’s contribution to the Design Proposal and Final Report and convert group marks into individual marks. Students who do not complete Sparkplus with meaningful feedback are unable to appeal resulting RPF values for that task.

Detailed information for each assessment can be found on Canvas.

*Restrictions on the closed-book criteria will apply which include no access to mobile/smart phones, tablets, laptops, programable calculators or any other text storing digital devices during the in-class test and examination. Only a personally drafted 5-page hand-written note sheet (double-sided) is allowed within these tests.

Assessment criteria

The University awards common result grades, set out in the Coursework Policy 2014 (Schedule 1).

As a general guide, a high distinction indicates work of an exceptional standard, a distinction a very high standard, a credit a good standard, and a pass an acceptable standard.

Result name	Mark range	Description
High distinction	85 - 100	Awarded when you demonstrate the learning outcomes for the unit at an exceptional standard, as defined by grade descriptors or exemplars outlined by your faculty or school.
Distinction	75 - 84	Awarded when you demonstrate the learning outcomes for the unit at a very high standard, as defined by grade descriptors or exemplars outlined by your faculty or school.
Credit	65 - 74	Awarded when you demonstrate the learning outcomes for the unit at a good standard, as defined by grade descriptors or exemplars outlined by your faculty or school.
Pass	50 - 64	Awarded when you demonstrate the learning outcomes for the unit at an acceptable standard, as defined by grade descriptors or exemplars outlined by your faculty or school.
Fail	0 - 49	When you don’t meet the learning outcomes of the unit to a satisfactory standard.

For more information see guide to grades.

Use of generative artificial intelligence (AI)

You can use generative AI tools for open assessments. Restrictions on AI use apply to secure, supervised assessments used to confirm if students have met specific learning outcomes.

Refer to the assessment table above to see if AI is allowed, for assessments in this unit and check Canvas for full instructions on assessment tasks and AI use.

If you use AI, you must always acknowledge it. Misusing AI may lead to a breach of the Academic Integrity Policy.

Visit the Current Students website for more information on AI in assessments, including details on how to acknowledge its use.

Late submission

In accordance with University policy, these penalties apply when written work is submitted after 11:59pm on the due date:

Deduction of 5% of the maximum mark for each calendar day after the due date.
After ten calendar days late, a mark of zero will be awarded.

This unit has an exception to the standard University policy or supplementary information has been provided by the unit coordinator. This information is displayed below:

Standard late penalty applies as outlined in Assessment Procedures 2011.

Academic integrity

The University expects students to act ethically and honestly and will treat all allegations of academic integrity breaches seriously.

Our website provides information on academic integrity and the resources available to all students. This includes advice on how to avoid common breaches of academic integrity. Ensure that you have completed the Academic Honesty Education Module (AHEM) which is mandatory for all commencing coursework students

Penalties for serious breaches can significantly impact your studies and your career after graduation. It is important that you speak with your unit coordinator if you need help with completing assessments.

Visit the Current Students website for more information on AI in assessments, including details on how to acknowledge its use.

Learning support

Simple extensions

If you encounter a problem submitting your work on time, you may be able to apply for an extension of five calendar days through a simple extension.  The application process will be different depending on the type of assessment and extensions cannot be granted for some assessment types like exams.

Special consideration

If exceptional circumstances mean you can’t complete an assessment, you need consideration for a longer period of time, or if you have essential commitments which impact your performance in an assessment, you may be eligible for special consideration or special arrangements.

Special consideration applications will not be affected by a simple extension application.

Using AI responsibly

Co-created with students, AI in Education includes lots of helpful examples of how students use generative AI tools to support their learning. It explains how generative AI works, the different tools available and how to use them responsibly and productively.

Support for students

The Support for Students Policy reflects the University’s commitment to supporting students in their academic journey and making the University safe for students. It is important that you read and understand this policy so that you are familiar with the range of support services available to you and understand how to engage with them.

The University uses email as its primary source of communication with students who need support under the Support for Students Policy. Make sure you check your University email regularly and respond to any communications received from the University.

Learning resources and detailed information about weekly assessment and learning activities can be accessed via Canvas. It is essential that you visit your unit of study Canvas site to ensure you are up to date with all of your tasks.

If you are having difficulties completing your studies, or are feeling unsure about your progress, we are here to help. You can access the support services offered by the University at any time:

Support and Services (including health and wellbeing services, financial support and learning support)
Course planning and administration
Meet with an Academic Adviser

Weekly schedule

WK	Topic	Learning activity
Multiple weeks	Independent study and working on assignments	Placement (78 hr)
Week 01	Course Introduction, aerospace vehicles and solid mechanics	Lecture (2 hr)
Week 01	Introduction to solidworks and part generation	Tutorial (2 hr)
Week 02	Load factors, safety factors, materials and failure loads	Lecture (2 hr)
Week 02	Multi-sections solid, taper, instance generation and introduction to sketch tracer	Tutorial (2 hr)
Week 03	Truss frames, margins of safety, optimisation	Lecture (2 hr)
Week 03	introduction to sheetmetal design	Tutorial (2 hr)
Week 04	Regulations and loads. The design process and reporting	Lecture (2 hr)
Week 04	Advanced Sheetmetal Design	Tutorial (2 hr)
Week 05	Engineering Drawings: introduction	Lecture (2 hr)
Week 05	Assembly Design	Tutorial (2 hr)
Week 06	Mid-Term Quiz	Lecture (2 hr)
Week 06	Kinematics	Tutorial (2 hr)
Week 07	Engineering Drawings: Dimensions and Tolerance	Lecture (2 hr)
Week 07	In-Class CAD Assessment	Tutorial (2 hr)
Week 08	Joints and Fasteners	Lecture (2 hr)
Week 08	Engineering Drawings	Tutorial (2 hr)
Week 09	Lugs	Lecture (2 hr)
Week 09	Engineering Drawings	Tutorial (2 hr)
Week 10	Beams	Lecture (2 hr)
Week 10	Surface Modeling	Tutorial (2 hr)
Week 11	Introduction to Thin-walled Structures, Modifications and Repair	Lecture (2 hr)
Week 11	Support for CAD and Group Projects	Tutorial (2 hr)
Week 12	Extended Topics	Lecture (2 hr)
Week 12	Support for CAD and Group Projects	Tutorial (2 hr)
Week 13	Course review	Lecture (2 hr)
Week 13	Group Project Demonstration and Oral Examination	Tutorial (2 hr)

Attendance and class requirements

The 2 hour lectures and 2 hour tutorial session will be delivered face-to-face. Attendance is required for participation in discussions. Students enrolled within this unit must attend the scheduled assessments.

Study commitment

Typically, there is a minimum expectation of 1.5-2 hours of student effort per week per credit point for units of study offered over a full semester. For a 6 credit point unit, this equates to roughly 120-150 hours of student effort in total.

Required readings

Main Textbooks:

Jean-Claude Flabel, Practical Stress Analysis for Design Engineers, First Edition, Lake City Publishing Company 1997

E. F. Bruhn, Analysis and Design of Flight Vehicle Structures, Jacobs Publishing, Inc. 1973

FAA-H-8083 Aviation Maintenance Technician Handbook - Airframe

Michael C. Y. Niu, Airframe Structural Design, Second Edition, Hong Kong Conmilit Press Ltd. 2006

Warren C. Young and Richard G. Budynas, Roark's Formulas for Stress and Strain, Seventh Edition, 2002

Federal Aviation Regulations, FAR 23, Airworthiness Standards: Normal Category Airplanes

Federal Aviation Regulations, FAR 25, Airworthiness Standards: Transport Category Airplanes

DOT/FAA/AR-MMPDS, Metallic Materials Properties Development and Standardization (MMPDS)

CMH-17, Composite Materials Handbook

Ashby, M. F.; Materials Selection in Mechanical Design, Butterworth-Heinemann, 2010.

Boothroyd, G.; Product Design for Manufacturing and Assembly, Taylor and Francis Group Ltd., 2011.

Campbell, F. C.; Manufacturing Technology for Aerospace Structural Materials, Elsevier, 2006.

Megson, T. H. G.; An Introduction to Aircraft Structural Analysis, Butterworth-Heinemann, 2010.

Baker, A. A., Dutton, S. and Kelly, D.; Composite Materials for Aircraft Structures, AIAA Education Series, 2004

Roskam, J.; Airplane Design Part V: Component Weight Estimation, ROSKAM AVIATION & ENGINEERING, 1989

Can be accessed via the Sydney Library portal (https://www.library.sydney.edu.au/) or through the following link. https://ebookcentral.proquest.com/lib/usyd/detail.action?docID=862036

Learning outcomes

Learning outcomes are what students know, understand and are able to do on completion of a unit of study. They are aligned with the University's graduate qualities and are assessed as part of the curriculum.

Outcomes
Graduate qualities

At the completion of this unit, you should be able to:

LO1. Describe, understand and interpret the role of trade-off study, performance, manufacture and assembly within the overall aerospace design process based on the relevant regulations and certification requirements
LO2. Development and analysis three-dimensional computer aided design (CAD) models specific for complex aerospace components. Develop the ability to interpret, reverse engineer and draft engineering drawings in the design of an aerospace component or assembly.
LO3. Apply computer aided design principles for the design, assembly and testing of well-defined aerospace components.
LO4. Perform basic stress and deflection analysis using referenced equations in compliance with Australian and International standards/regulations.
LO5. Evaluate and select engineering materials, design methodologies, and assembly processes based on manufacturing opportunities and constraints relevant to the aerospace industry.
LO6. Design and verify appropriateness of analysis of a complex aerospace component accounting for aircraft performance, certification and design requirements. Developing the ability to process large amount of information to select appropriate methodology of analysis and design appropriate to the given specifications.
LO7. Understand the role of safety factor, margin of safety, limit and ultimate loads, V-N diagrams, damage tolerance and design approaches of aerospace structures, components and advanced composite materials subjected to quasi-static and fatigue loading.

Graduate qualities

The graduate qualities are the qualities and skills that all University of Sydney graduates must demonstrate on successful completion of an award course. As a future Sydney graduate, the set of qualities have been designed to equip you for the contemporary world.

GQ1	Depth of disciplinary expertise Deep disciplinary expertise is the ability to integrate and rigorously apply knowledge, understanding and skills of a recognised discipline defined by scholarly activity, as well as familiarity with evolving practice of the discipline.
GQ2	Critical thinking and problem solving Critical thinking and problem solving are the questioning of ideas, evidence and assumptions in order to propose and evaluate hypotheses or alternative arguments before formulating a conclusion or a solution to an identified problem.
GQ3	Oral and written communication Effective communication, in both oral and written form, is the clear exchange of meaning in a manner that is appropriate to audience and context.
GQ4	Information and digital literacy Information and digital literacy is the ability to locate, interpret, evaluate, manage, adapt, integrate, create and convey information using appropriate resources, tools and strategies.
GQ5	Inventiveness Generating novel ideas and solutions.
GQ6	Cultural competence Cultural Competence is the ability to actively, ethically, respectfully, and successfully engage across and between cultures. In the Australian context, this includes and celebrates Aboriginal and Torres Strait Islander cultures, knowledge systems, and a mature understanding of contemporary issues.
GQ7	Interdisciplinary effectiveness Interdisciplinary effectiveness is the integration and synthesis of multiple viewpoints and practices, working effectively across disciplinary boundaries.
GQ8	Integrated professional, ethical, and personal identity An integrated professional, ethical and personal identity is understanding the interaction between one’s personal and professional selves in an ethical context.
GQ9	Influence Engaging others in a process, idea or vision.

Outcome map

Learning outcomes	Graduate qualities
Learning outcomes

Responding to student feedback

This section outlines changes made to this unit following staff and student reviews.

This is a unit that is developed within the Aeronautical Engineering Stream (for various stream specialization pathways). This Unit of Study (UoS) combines key knowledge in Aircraft Design Principles and Processes followed Computer Aided Design relevant to the Aerospace/Aeronautical Industry. 2026: The structure and content of the course have been adjusted to better reflect industry needs. Introduced a Final Exam to replace a Quiz.

Additional information

N/A

Additional costs

N/A

Site visit guidelines

N/A

Work, health and safety

N/A

Disclaimer

Important: the University of Sydney regularly reviews units of study and reserves the right to change the units of study available annually. To stay up to date on available study options, including unit of study details and availability, refer to the relevant handbook.

To help you understand common terms that we use at the University, we offer an online glossary.

Current students

Overview

Overview

Unit details and rules

Teaching staff

Assessment

Assessment

Assessment summary

Assessment criteria

Use of generative artificial intelligence (AI)

Late submission

Academic integrity

Learning support

Learning support

Simple extensions

Special consideration

Using AI responsibly

Support for students

Weekly schedule

Weekly schedule

Attendance and class requirements

Study commitment

Required readings

Learning outcomes

Learning outcomes

Graduate qualities

Outcome map

Responding to student feedback

Responding to student feedback

Additional information

Additional information

Additional costs

Site visit guidelines

Work, health and safety

Disclaimer

On this page

Useful links

AERO9460: Aerospace Design 1

Semester 2, 2026 [Normal day] - Camperdown/Darlington, Sydney

Overview

Overview

Unit details and rules

Teaching staff

Assessment

Assessment

Assessment summary

Assessment criteria

Use of generative artificial intelligence (AI)

Late submission

Academic integrity

Learning support

Learning support

Simple extensions

Special consideration

Using AI responsibly

Support for students

Weekly schedule

Weekly schedule

Attendance and class requirements

Study commitment

Required readings

Learning outcomes

Learning outcomes

Graduate qualities

Outcome map

Responding to student feedback

Responding to student feedback

Additional information

Additional information

Additional costs

Site visit guidelines

Work, health and safety

Disclaimer

On this page

Useful links