Collier Aerospace has provided its HyperX computer-aided engineering (CAE) software to Swift Engineering for the structural sizing, analysis and test validation of the X-59 aircraft’s nose cone.

The X-59, an experimental aircraft from Lockheed Martin Skunk Works, is part of NASA’s Quiet Supersonic Technology (Quesst) mission, which aims to reduce the loud sonic booms produced during supersonic flight.

Swift Engineering was contracted to build and test the X-59’s 35 ft.-long nose cone, designed to manage aerodynamic pressure waves during supersonic flight. The nose cone is a critical component, as it reduces the shock waves that result in sonic booms, creating a quieter “thump” instead.

Using Collier’s HyperX software, Swift Engineering has been able to reduce the nose cone's weight by over 25% while maintaining its dimensional stability. Collier’s software facilitated the evaluation of design alternatives, performed stress analysis and helped optimise the structure for mass reduction.

“The Collier Aerospace software played a critical role throughout this high-visibility project to design, engineer and build the X-59 nose structure,” says Bill Giannetti, technical consultant at Swift Engineering. “At the outset, when the team from Skunk Works explained how important lightweighting was, I had so much confidence in the software that I was convinced we would remove 100 pounds from the nose cone. However, we surpassed that goal by achieving a significant weight savings of over 25 percent on the nose cone structure.”

The software enabled Swift to remove unnecessary material layers and optimise the structure by adjusting ply-layup schedules, core panel thickness and edge band dimensions. Through rapid structural sizing and finite element analysis, the team could quickly iterate designs, achieving structural optimisation and load path convergence.

The X-59’s unique geometry, particularly its elongated nose cone, is intended to reduce noise pollution from supersonic flight, which could potentially lead to the lifting of a decades-long ban on commercial supersonic aeroplanes flying over land.

James Ainsworth, Vice President of Engineering Services at Collier Aerospace, says: “We’re proud that our software helped Swift Engineering meet the high expectations of Lockheed Martin Skunk Works. The credibility of our solution and its powerful sizing and analytical capabilities were key factors in their decision to use our software.”

The X-59 is slated for its first flight in 2025 with hopes of revolutionising commercial supersonic travel.