SAE Aero UW Soars to New Heights

Last spring, a group of determined students attended the College of Engineering’s student org bash with nothing more than a model airplane and a dream. The goal? Get enough students interested in starting an SAE Aero competition team. Today, that same group of students just returned from their first competition in Van Nuys, California. Back from their adventure out west, the group reflects on their humble beginnings and is already setting their sights on the skies for next year!

SAE Aero UW Origins

The motivation behind starting SAE Aero UW at UW-Madison was to bridge the gap between learning aerospace concepts in the classroom and applying them through hands-on experiences. Although the College of Engineering has many hands-on competition teams, the students were driven to create a group for students passionate about aerospace engineering with a curiosity about what it truly takes to build a functional aircraft. They wanted to create a space where students could take their academic knowledge and turn it into something tangible – an aircraft that could take flight!

SAE Aero Design Competition

To put more emphasis behind these goals, the group set their sights on the SAE Aero Design Regular Class competition. This 3-day competition challenges teams to design an aircraft that can carry the highest payload possible while maximizing wingspan (within a 15-ft wingspan and 55-lb weight limit). Scoring is based on the top three flight scores, with a wingspan bonus. The goal is to find the best balance between lift, weight, and structural efficiency, pushing teams to be strategic in their design, while focusing on both aerodynamic performance and precise planning.

Keeping these objectives in mind, the team set out to build an aircraft with a high-aspect-ratio wing to generate greater lift. This process included many brainstorms, deliberations, trial and error, and research to select the right electronics, control surfaces, and materials. In the end, UW SAE Aero created an aircraft using aluminum and balsa wood for structural integrity, and foam for aerodynamics shaping – prioritizing strength without compromising weight. These components were then covered in Monokote, a heat-shrink film that forms the outer skin of the aircraft.

With a structurally sound plane, the group headed to California, where they placed 22^nd out of 27 teams. Although this placement may not have been as high as the team would have liked, they’re still incredibly proud of their accomplishments. SAE Aero UW president, Aiden Brion, described, “the biggest win for us was proving we could start from nothing, build a working aircraft, and make it to the competition in our very first year.”

Brion further explained participating in the competition allowed the group to connect with other teams from around the world and learn from their experiences. This network offered valuable insights on improving materials selection, structural design, overall efficiency, and streamlining workflow. Brion stated, “above all, it reminded us why we’re doing this – to learn, grow, and have a great time building and flying planes.”

Soaring Ahead

At the beginning of the year, the group had two main goals: 1) create an aerospace focused club and ensure its longevity, and 2) design and build an aircraft for a competition and have a successful flight. With their first year behind them, it is safe to say these goals were achieved. But this is just the beginning for SAE Aero UW – the team is already setting their sights on more ambitious projects and long-term growth. They just completed a full review of their season – identifying what worked well, what needs improvement, and what should be avoided moving forward. And they’re holding elections to fill key leadership roles that will shape the future of the team.

To capture the team’s forward-looking outlook, Brion states, “We’re incredibly excited about the passion our members bring, and we’re looking forward to building on the momentum we’ve created. Our goals for next year are clear: place higher at the competition and bring an even larger group of students to represent UW-Madison. We’re just getting started- and we’re ready to compete with the best.”

With renewed focus and a clear vision, SAE Aero UW is poised to take their progress to new heights in the seasons ahead.

Special thank you to Aiden Brion for sharing all photos, testimonies, and competition details.