Steps in the manufacture of the Stork prototype :

Step 1: Hot wire cutting of the trapezoidal wing profiles in expanded polystyrene

Step 2: Assembly of the trapezoids to obtain the wing with PU glue

Step 3: Cutting the 10 panels composing the fuselage with a CNC milling machine in extruded polystyrene

Step 4: Assembly of the panels with PU glue to obtain the shape of our fuselage

Step 5: Manufacturing of wing keys based on carbon fibre and polystyrene placed in a previously manufactured mould

Step 6: Installation of the glass fibre, carbon fibre and wood overlay with resin on the top surfaces (wing, rudders and stabilizer)

Step 7: Vacuuming to wait for the top surfaces to harden (minimum 24-hour waiting time)

Step 8: Installation of the sleeves receiving the wing keys (these allow the wings to be connected to the fuselage)

Step 9: Installation of the glass fibre, carbon fibre and wood overlay with resin on the underside (wing, rudders and stabiliser)

Step 10: Vacuuming to wait for the intrados to harden (minimum 24-hour waiting time)

Step 11: Relaxation break by turning our wing into a sword! (the wing weighs only 2 kg)

Step 12: Fabrication of the carbon rods and holes that will receive the tubes to connect the wings and rudders

Step 13: Manufacturing and installation of wooden couples and finishes at the ends

Step 14: Adding winglets printed in 3D

Step 15: Flaps cutting

Step 16: Cutting the shutters housing the servomotors

Step 17: Testing the servomotors

Step 18: Fiberglass and resin installation to harden the fuselage

Step 19: To be continued…