Speedfest: Critical design review, Black Team 2025

This report presents the Critical Design Review (CDR) for the Black Team’s 2025 Speedfest competition aircraft, submitted to fulfill of the honors thesis requirement. The aircraft is a high-performance, internal combustion-powered pylon racer and aerobatic aircraft, designed around an unmodified Desert Aircraft DA35 engine. Aerodynamic optimization led to the selection of a 60 in wing span with a NACA 2412 airfoil and a 20x13 two-blade propeller, which predicts that the aircraft can collect 22 flags during the pylon racing mission. Propulsion testing included power output measurements, fuel system sizing, and development of a lightweight custom muffler. The primary structures were fabricated using fully molded composite construction, with material testing guiding the design for minimum weight and sufficient stiffness. The final weight is estimated at 9 pounds, with the center of gravity located 0.31 inches aft of quarter chord. This report documents the multidisciplinary design process culminating in a cost-effective, competition-ready aircraft.