The KA350 King Air is a twin-engine turbo-prop aircraft based at RAAF Base, Sale, and is used extensively for training of Air Force Mission Aircrew and Navy Aviation Warfare Officers.
To better prepare each pilot for flight they have to pass a unique test involving aircraft faults. These faults are known as Foreign Object Damage (FOD) and simulate real world situations such as flat tyres, oil leaks, wasp nest in fuel drain hole, or an open petrol cap. RAAF needed new training solutions with minimal disruptions to their general operations.
A Virtual Reality (VR) training simulation was proposed using a combination of 3D scanning and photogrammetry technology. Engaging with WYSIWYG 3D (GoProto’s 3D scanning division), realistic digital twins were created that captured the colours and textures for a virtual world.
Each aircraft fault was physically recreated so it could be photographed and scanned using handheld and terrestrial scanners, as well as 360° array of high resolution digital cameras. This was all done at night using professional lighting to minimise shadowing effects and achieve optimum results.
Within five days, our scanner operators obtained the necessary data, which was then processed back at WYSIWYG 3D’s facility so the aircraft geometries could be rebuilt as full colour 3D digital (computer) models.
The data collected by WYSIWYG 3D enabled the KA350 digital twin aircraft to be integrate into the Euclideon 3D VR platform. In total, it took our team 10 days to complete the project, from scanning the aircraft to delivery of the finished files.
Wearing VR glasses, pilots can interact with the digital plane, allowing the tester to select different scenarios the pilot has to overcome. RAAF has 700 pilots and each pilot needs 24 weeks of training to qualify. A VR training solution helps ensure pilots are properly trained in aircraft maintenance to minimise disruptions caused by aircraft on ground (AOG).
Above: Scanned data of landing gear & tyre. Features colours & textures suitable for VR
“Hey Guys, Hope all is well! I just received the sheet metal parts and assembled them onto the prototype it belongs to and it’s perfect! Just wanted to let you know you guys did a great job!” — Daren Northcotte, Design Engineer – Sydney, NSWView testimonials
The most powerful aspect of additive manufacturing for a designer is the freedom to create complex forms and the […]Read case study
Figure 4® RUBBER-65A BLK is a new ‘production grade’ mid-tear strength elastomer featuring strength and durability, as well as […]Read blog post