Colin Alexander Sledge

Step 1: Get an Airfoil Dat File

An airfoil dat file

can be found
on the internet,
such as
airfoiltools.com
Must have a file
format that
begins at the
trailing edge
and ends at the
trailing edge!

Step 1: Get an Airfoil Dat File

(Airfoiltools.com)

Once an airfoil
is chosen,
select the Selig
format
Open notepad
or an
appropriate text
editor

Step 1: Get an Airfoil Dat File

(Airfoiltools.com)

Copy and past

the data into
notepad
Delete the title
information and
line up the
numerical data
Save the file as
a .txt format
with the airfoil
name

Copy and
Paste

Step 2: Open Airfoil File in Excel

Open Excel or
similar program
Open file -> All
File Types ->
airfoil_name.txt
A pop-up menu
will appeared
titled Text
Import Wizard

Step 2: Open Airfoil File in Excel

Make sure
Delimited is
selected
A preview of
your .txt file
should show
Click the Next
button

Step 2: Open Airfoil File in Excel

Selected
Space as the
Delimiter
A preview of
your .txt file
should show
with black lines
separating the
columns
Click the Next
button

Step 2: Open Airfoil File in Excel

Select General
for the Column
data format
(default
selection)
Confirm the data
format looks
appropriate
Click the Finish
button

Step 3: Modify Airfoil File in Excel

Delete

Once in Excel,
delete blank
columns so data
starts in first column
Check the data for
repeated data
points next to each
other; such as
multiple 0.00 | 0.00

Step 3: Modify Airfoil File in Excel

To open an airfoil in
Solidworks, the data
must contain X,Y, and Z
columns
A column of zeros must
be added depending on
which plane the airfoil
should be in
Front Plane add
zeros to 3rd column
Top Plane add zeros
to 2nd column
Right Plane add
zeros to 1st column

Added zeros (Front

Plane)

Step 3: Modify Airfoil File in Excel

Save the airfoil File

-> Save as
The same airfoil
name may be used
Ensure the Save as
type is Text (Tab
delimited)(*.txt)
Click the Save
button

Step 3: Modify Airfoil File in Excel

If saving as the same

airfoil name, confirm
Save as replacing file
A pop-up will warn
that some features
are not compatible
with Text (Tab
delimited)
Confirm the warning
by clicking Yes
Make sure to close
Excel

Step 4: Open Airfoil File in

Solidworks

In Solidwork, open
a new part
document
In the Features
tab, select the
Curves feature
drop-down menu
In the Curves
feature, select
Curve Through
XYZ Points

Step 4: Open Airfoil File in

Solidworks

In the Curve File

menu, select the
Browse button
In the file menu,
select Text File
(*.txt) as the file
type
Browse for the
desired airfoil file

Step 4: Open Airfoil File in

Solidworks

Find the
airfoil_name.txt file
and select open
In Solidworks, the
Curve File menu will
populate with the
airfoil data
A yellow preview
will show in the
appropriate plane
Click OK button

Step 5: Create Airfoil Sketch in

Solidworks

A Curve1 feature
will show in the
feature tree as well
as the airfoil curve
in the workspace
Right click on
Curve1 -> Select
Feature Properties > Change name to
airfoil name

Step 5: Create Airfoil Sketch in

Solidworks

Select the
appropriate
plane and
insert a new
sketch
The airfoil
curve will be
shown in blue;
DO NOT hide
at this time

Step 5: Create Airfoil Sketch in

Solidworks

Select the airfoil

curve an then
select Convert
Entities in the
Sketch Tool Bar
This is create a
sketch driven by
the airfoil curve
A black sketch will
now be overlaying
the blue airfoil
curve
Confirm the sketch
by selecting the
green arrow in the
Convert Entities
feature menu

Step 5: Create Airfoil Sketch in

Solidworks

Zoom in to the
trailing edge of
the airfoil and
confirm that the
curve is closed
and connected
If the trailing
edge is
open/broken,
please see
Appendix A for
fixing the
trailing edge
sketch
Note: This airfoil imported with closed/connected
trailing edge

Step 5: Create Airfoil Sketch in

Solidworks

Zoom to fit the

airfoil in the
screen
Add a
centerline from
the leading
edge to the
trailing edge
Provide a
reference
dimension for
the length of
this line

Step 5: Create Airfoil Sketch in

Solidworks

Many airfoil
.dat files
import scaled
to 1 unit chord
length
Select the
entire sketch
and select
Scale Entities
in the sketch
toolbar

Step 5: Create Airfoil Sketch in

2
Solidworks
In the scaling
feature property
menu, select the
leading edge as
the point to scale
about
Scale the entities
by the desired
length over the
reference chord
dimension
Do not select
copy (unless you
need to keep the
small airfoil in
the sketch)

Step 5: Create Airfoil Sketch in

Solidworks

A preview will
appear with
the large
airfoil
If satisfied
with the
preview, click
the green
arrow to
accept the
transformation

Preview of airfoil scaled by a factor of 8

Step 5: Create Airfoil Sketch in

Solidworks

Zoom to fit; if
satisfied with
the sketch,
exit the sketch
editor
The airfoil
curve may be
hidden to
make the
sketch easier
to view

Step 6: Create Airfoil Feature in

Solidworks
If a straight wing
is desired,
extrude the
sketch for design
wingspan
Make sure to
extrude the wing
Mid Plane to
maintain
centerline
reference
To create wings
with taper,
sweep, dihedral,
and washout,
please see
Appendices B-E

Finished Wing!

Appendix A: Fixing the trailing

edge of an imported airfoil .dat
file

When the imported

airfoil .dat file is
missing the trailing
edge, this will
prevent the profile
from generating a
solid body feature

This appendix will

provide a method to
fixing the missing
trailing edge while
maintaining the
imported airfoil
shape

Step 1: Repair Airfoil Trailing

Edge

Import the
airfoil curve
and convert
entities as
usual
Zoom in to the
trailing edge of
the airfoil and
confirm that the
curve is open
and
disconnected
Note: This airfoil imported with
open/disconnected trailing edge

Step 1: Repair Airfoil Trailing

Edge

In the sketch
tools, use the
line tool
Draw two lines,
starting at each
end point on
the trailing
edge, to some
arbitrary
location
Do not apply
any sketch
relations at this
time

Step 1: Repair Airfoil Trailing

Edge

Choose one of the

lines, select the
airfoil sketch and
the line while
holding the CTRL
key, and apply the
tangent sketch
relation
Apply the same
process for the
second line
Note: if the lines
move on the airfoil
when the tangent
relation is applied,
use a fix relation to
fix the line
endpoint on the
airfoil spline.

Note: 1 depicts the tangent sketch relation

already applied to the airfoil spline and the first
line sketch

Step 1: Repair Airfoil Trailing

Edge
After applying
the tangent
sketch relations
to both lines,
the trailing
edge should be
connected
Use the sketch
trim tool to
remove the
excess lines
The repaired
trailing edge
should be
closed and
connect

Step 1: Repair Airfoil Trailing

Edge
After applying
the tangent
sketch relations
to both lines,
the trailing
edge should be
connected
Use the sketch
trim tool to
remove the
excess lines
The repaired
trailing edge
should be
closed and
connect

Step 2: (Optional) Form 1 spline

sketch feature

This optional
step produced
a single closed
spline sketch
as opposed to
3 sketch
features
Select the 3
sketch
components
Tools -> Spline
Tools -> Fit
Spline

Step 2: (Optional) Form 1 spline

sketch feature

In the Fit Spline

feature menu,
the tolerance
box shows how
closely the
spline is
matching the
sketch features
Turn the dial to
the lowest
tolerance
possible without
losing the pink
preview

Step 2: (Optional) Form 1 spline

sketch feature

The finished
spline will be
one continuous
sketch features
Scale and
extrude the
wing as usual

Appendix B: Creating a wing with

Sweep, Taper, Dihedral, and
Washout (Twist)

Sweep, Taper,
Dihedral, and
Washout are all
integral aspects of
an aircraft wing.
Most aircraft wings
utilize at lease one
of these aspects for
better performance.

This appendix will

provide a method to
create a wing that
has sweep, taper,
dihedral, and
washout. This will
specifically resemble
a commercial
aircraft wing but can
be applied to other
aircraft and even
propellers.

Step 1: Create Wing Root Chord

Designate your BL
0.0 Plane or Front
Plane as the Root
Plane
Insert the airfoil as
normal and scale
the airfoil to the
root chord length.
Draw a chord line;
a line that is
horizontal from the
leading edge to
the trailing edge.
Insert a point and
define it so it is at
the quarter chord,
.25*Chord, starting
at the leading
edge
Exit the sketch
when complete

Step 2: Create Wing Tip Plane

Using
Reference
Geometry,
create a plane
for the tip chord
of the wing
The tip chord
plane should
be of the
total wing span
from the root
chord plane
The direction of
the plane will
not matter due
to symmetry

Step 2: Create Wing Tip Plane

Rename the
plane Wing
Tip Plane or
Tip Plane
Right click on
Plane1 ->
Select
Properties ->
Change name
to Tip Plane

Step 3: Create Wing Sweep

The wing sweep is

defined at the
sweep angle of the
quarter chord line;
from the quarter
chord of the root
chord to the
quarter chord of
the tip plane
To start, insert a
sketch on the top
plane or WL 0.0
plane
Insert a
construction line
sketch from the
quarter chord point
of the root airfoil
and set it
coincident to the
wing tip plane

Step 3: Create Wing Sweep

Insert another
construction line
sketch from the
quarter chord point
of the root airfoil,
ensuring it had a
vertical constraint
This vertical line
will be used to
define the sweep
angle
Using smart
dimension, define
the angle between
the vertical line
and sweep line
Exit the sketch
when complete

Step 4: Create Wing Dihedral

The wing dihedral is

the angle the wing
makes with a horizontal
datum
The usual convention is
for dihedral to be the
wing angled upward
with anhedral is when
the wing is angled
downward
To start, insert a sketch
on the right plane or
STA 0.0 plane* and
create a construction
line from the quarter
chord point of the root
wing section coincident
to the tip section plane
*Note that the front
plane and subsequent
parallel planes are the
true wing stations, as
opposed to the
convention shown

Step 4: Create Wing Dihedral

Insert a
horizontal
construction
line or use the
sweep line as
a reference
for the
dihedral angle
Using the
smart
dimension
tool, set the
dihedral angle

Step 5: Locate Wing Tip Section

The sweep line and

dihedral line are
used to locate the
quarter chord of the
wing tip section
Insert a sketch on
the wing tip plane
Draw a horizontal
line starting from the
dihedral point,
backward for an
arbitrary distance*
Draw a vertical line
starting from the
sweep point, upward
for an arbitrary
distance*
*Note that you may
need to use the
pierce sketch
relation to locate the
line starting point
correctly

Step 5: Locate Wing Tip Section

The intersection
of the two lines
is the location of
the wing tip
section quarter
chord
Place a point at
the intersection
of the two lines
or trim the lines
to create the
intersection point
Exit the sketch
and rename the
sketch Wing Tip
Quarter Chord
Point

Step 6: Insert the tip section and

the wing taper

Insert a
sketch on the
wing tip plane
Select the root
chord select
Convert
Entities in the
sketch toolbar

Step 6: Insert the tip section and

the wing taper

Move the
converted airfoil
section near the
tip quarter chord
point using the
Move Entities in
the sketch toolbar
Select the airfoil
sketch then select
the leading edge
as the point to
move from
move the cursor to
the new location
and left click
then right click to
confirm

Step 6: Insert the tip section and

the wing taper
With the airfoil
section in this
arbitrary location,
select Scale Entities
in the sketch toolbar
Select the airfoil
sketch and click on
the leading edge as
the point to scale
about
For the scaling
factor, input the
taper ratio desired*
*Note that if using an
airfoil section other
than the root section,
tip scaling factor will
not be the precise
taper ratio as this is
defined as the ratio
of the tip chord to
the root chord

Step 6: Insert the tip section and

the wing taper

Zoom to the wing

tip airfoil section
Draw a horizontal
chord line starting
at the leading
edge, terminating
at the trailing edge
Place a point on
the chord line and
dimension
appropriately so
this point is
precisely at the
quarter chord
position of this
section

Step 6: Insert the tip section and

the wing taper

Once again, select

the Move Entities
sketch feature
Select the airfoil
section as well as
the chord line and
quarter chord point
to move
Click the quarter
chord point as the
point to start entity
move
Click the wing tip
quarter chord
location, found
earlier, as the
terminating point
for the move
entities feature

Step 7: Add wing tip washout as

necessary
Wing washout is
defined as a
difference in the
incidence angle of
the wing tip with
respect to the wing
root
Wing wash-out is the
tip having a lower
angle of incidence
with respect to the
root while wash-in is
the tip having a
greater angle of
incidence with
respect to the root
Generally, only
wash-out is utilized
When generating a
propeller model, this
step will be used to
provide the blade
station twist

Step 7: Add wing tip washout as

necessary
To apply washout or wash-in,
select the
Rotate Entities
from the sketch
tool bar
Select the airfoil
section, the
quarter chord
point, and the
chord line as the
entities to rotate
Select the
quarter chord
point as the point
to rotate about

Step 7: Add wing tip washout as

necessary

Select an angle
to rotate the
sketch
Visually confirm
the airfoil
section rotates
in the correct
direction
Once satisfied,
confirm the
rotation, exit
and rename the
sketch Wing
Tip Section

Step 8: Generate wing loft

Select and Isometric

view and confirm
that the root and tip
chords are visually in
the correct locations
Select the Loft
Boss/Base tool from
the features tool bar
Select the root chord
first, then the tip
chord as the Loft
Profiles
If the loft does not
immediately show a
preview, drag the
main connector to
the trailing edge on
each airfoil section
The loft should
generate a preview;
if correct confirm the
loft

Note: Connector shown having been

Dragged to the trailing edge on each
section for loft to generate

Step 9: Mirror Wing

To complete the
wing, select the
Mirror tool from
the features
toolbar
Select the front
plane or BL 0.0
as the mirror
plane
Choose the wing
loft as the body
to mirror*
*Note: use the
Bodies to Mirror
selection as
opposed to the
Features to
Mirror selection

Step 10: Finish Build the Aircraft!

The steps taken
to create the
wing can largely
be used for the
remain
aerodynamic
surfaces such as
the tail sections,
pylons, and
engine
components
The nose section
and afterbody of
the aircraft
require many
surfacing tools
for best
appearance

Appendix C: Creating a Propeller

Propellers are
similar to wings but
utilize large amounts
of washout and
various blade taper.
For more
information, please
reference one of the
many publications
for propeller theory.

This appendix will

provide a method to
create a propeller
using varying
airfoils, chords, and
blade section
angles. Although
this method is for a
common aircraft
propeller, it can be
used for other
applications.

Step 1: Create Blade Station

Planes

Designate your
BSTA 0.0 Plane or
Right Plane as the
Root Plane
Insert the
necessary blade
station planes
according to your
propeller design.
Label each plane
based on its
distance from the
root plane
More blade
stations will give
the user greater
control over the
design, but too
many planes can
make the blade
difficult to loft.

Step 2: Import Airfoil Curves

As discussed
previously, import
the airfoil curves.
Make sure to change
the name of each
curve to represent
each airfoil section
as this will be hard to
distinguish after
many section have
been imported.
If this airfoil sections
import in the wrong
orientation, this can
be rotated later;
unless this section
are imported on the
incorrect plane.
For ease, hide each
curve after importing
to clean up the work
space.

Step 3: Setting Blade Station

Twist and Chord

According to your
propeller design,
you will have a
predetermined
airfoil, chord
length, and section
angle.
Insert a sketch on
the given blade
station plane.
Unhide the
appropriate airfoil
curve for the blade
station and
convert entities to
start the sketch.
Fix the trailing
edge where
necessary.

Step 3: Setting Blade Station

Twist and Chord

Scale the airfoil sketch

to the design chord
length at the blade
station.
As discussed
previously, insert a
point at the quarter
chord* of the section as
a reference for rotating
the section.
Select the rotation tool
and rotate the airfoil
section about the
rotation point to the
desired angle.
Use the move tool to
relocate the airfoil
section so the points of
rotation are
coincident**.
For ease of finishing
the propeller, make the
root section rotation
point coincident with
the origin.

*The rotation point can be a different chord position

based on the propeller design
** The points of rotation can be a different locations
based on the propeller design, but may impact loft.

Step 3: Setting Blade Station

Twist and Chord

Step 4: Lofting the First Blade

Once all of the blade

station airfoil sections have
been set in terms of the
airfoil, twist, and chord
length, the blade is ready
to be lofted.
Starting with the root,
select each section
sequentially, and adjusting
the main connector as
appropriate.
The main connector should
not cross across the loft as
this may introduce kinks if
the loft will even generate.
Dragging the main
connector to either the
leading edge or trailing
edge should produce a
smooth, continuous loft.
Guide curves can be used
to force the loft to follow a
path between defined
section if there is a low
number of sections to
generate the loft.

Step 4: Lofting the First Blade

Once the loft is
generated, the
Curvature tool can
be used to identify
kinks and
irregularities in the
loft.
Select the Evaluate
tab, then Curvature
to activate the tool.
The Curvature tool
will color the loft
according to the
radius of curvature
making it easy to
see shape areas and
potential problems.
This also allows you
to see if the loft
generated as
expected with
smooth transitions.

Step 5: Finishing the Blade Tip

Often times on a blade

or wing tip, it is
desirable to finish the
section with a smooth
curve as opposed to a
straight cutoff.
To begin the process,
add a blade tip plane
that is perpendicular to
the cutoff face and
using the tip section
chord line as a planar
reference.
*If a more complicated
shape is desired with
sections out of this
plane, more reference
geometry and guide
curves are needed and
will be a similar
process to lofting the
blade body.

1
2

Step 5: Finishing the Blade Tip

1

Insert a sketch on the

Blade Tip Plane and begin
by adding a terminal point
at the desired distance
from the current blade tip.
Exit the sketch for the
terminal point and insert a
NEW sketch for the guide
curve.
Begin by drawing a guide
curve from the trailing or
leading edge to the
terminal point. Make sure
that the curve is coincident
to the terminal point and
the edge of the blade*.
Exit the sketch and insert a
NEW sketch for the
second guide curve. As
before, make sure this is
coincident to the blade
edge and the terminal
point.
It is essential that the
guide curve is broken into
multiple parts for control
and to ensure the loft
generates.

*Often times the sketch will need to use the Pierce

relationship to ensure it is coincident to the blade surface.
1: Blade tip terminal point. 2: Leading edge guide curve.
3: Trailing edge guide curve.

Step 5: Finishing the Blade Tip

Enter the loft tool and

begin by selecting the
blade tip section sketch as
the first loft section.
For the next section, select
the tip terminal point. The
loft should show a preview
of something that looks
similar to a cone. The idea
is that the loft will generate
a conical section and then
it will be stretch to the
desired shape by the guide
curves.
Click the Guide Curve
Selection Box and select
the leading edge and
trailing edge guide curves.
If the loft does not produce
a desired result, the guide
curves may be over
constraining or the start
and end constraints may
need to be adjusted*.

*The start and end constraints can help smooth the loft
and blend the current loft to the adjacent loft, however, it
can also prevent the loft from generating so use with
caution.

Step 6: Finishing the propeller

To add the remain

blades, create an
axis of rotation
using reference
geometry
perpendicular to
the plane of
rotation.
Use the circular
pattern to produce
the desired
number of blades.
Even for 2-bladed
propellers, use the
circular pattern
tool as opposed to
the mirror tool to
ensure the blades
are in the proper
orientation.

Step 6: Finishing the propeller

Use the extrusion

or revolve tools to
create the
appropriate
propeller hubs and
spinner caps.
To add tip
markings or
spinner cap
markings, use the
split line tool in the
Features tab
Curves menu. This
will create a split
face that can be
colored at desired,
but will not affect
the part.

Step 7: Propeller References

Aircraft Propellers

Marine Propellers

http://www.pilotfriend.

http://www.propline.co

com/training/flight_trai
ning/fxd_wing/props.h
tm
http://www.aboutflight.
com/handbook-ofaeronauticalknowledge/ch-4aerodynamics-offlight/basic-propellerprinciples

m/Propeller-GeneralInformation/Propeller
_Terminology.htm
http://www.propellerp
ages.com/downloads/
Technology_guideline
s_for_efficient_design
_and_operation_of_s
hip_propulsors.pdf

THE END