ISO-Plane TRL3

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ISO-Plane TRL3

Overview

ISO-Plane TRL3 marks the transition from validated conceptual architecture (TRL2) to detailed engineering definition.

At this stage, the objective is to demonstrate analytical and experimental proof of critical subsystems, validate structural hypotheses, and prepare the program for industrial engagement.

TRL3 focuses on transforming a coherent digital mock-up into an engineering-driven, simulation-supported aircraft definition.

TRL Context

Technology Readiness Level 3 corresponds to:

  • Analytical and experimental proof-of-concept
  • Validation of key subsystems
  • Identification of technical risks
  • Structural and aerodynamic refinement
  • Preparation for pre-industrial maturation

TRL3 is the first phase where engineering depth becomes the primary driver of development.

TRL2 → TRL3 Transition

Achieved at TRL2

  • Global aircraft architecture validated
  • 3D digital mock-up completed
  • Loading system concept defined
  • Engine selection confirmed (PW150A)
  • Q400-based landing gear integration concept
  • Preliminary performance and mass estimation
  • Market and operational study

Objectives of TRL3

  • Detailed structural calculations (RDM)
  • Aerodynamic refinement and CFD validation
  • Ventral cargo door structural sizing
  • Central wing box optimization
  • Mechanized arm load path validation
  • Landing gear integration structural verification
  • Weight breakdown consolidation
  • Systems architecture refinement
  • First industrial technical exchanges

Technical Work Packages (TRL3)

1. Structural Engineering

  • Finite Element Analysis (FEA) of fuselage
  • Central wing box structural modeling
  • Pressurized cargo bay analysis
  • Ventral door reinforcement modeling
  • Load cases: flight, landing, container lift
  • Fatigue considerations

Primary objective: Validate structural feasibility of a 4 m diameter fuselage integrating a ventral opening.

2. Aerodynamics & Performance

  • CFD analysis of high-wing twin-boom configuration
  • Drag breakdown refinement
  • Propeller slipstream interaction studies
  • High-lift device optimization
  • Takeoff and landing performance reassessment
  • Updated range analysis

Primary objective: Validate aerodynamic assumptions and refine mission envelope.

3. Cargo Handling System Validation

At TRL3, the cargo handling system moves from concept validation to engineering verification.

The objective is clear: confirm that the autonomous loading architecture is not only innovative, but structurally and mechanically sound.

This phase is structured around three main validation pillars.

Kinematic realism

The robotic arms are analysed through detailed kinematic modelling. Their deployment sequence, articulation limits and retraction geometry are verified to ensure compatibility with the ventral door and fuselage structure. Clearance margins are carefully assessed, because small geometric assumptions at TRL2 can lead to significant mechanical constraints at TRL3.

Structural load transfer

Lifting an 8-ton container generates concentrated loads at the ISO corner interfaces. A complete load path analysis is therefore conducted — from the twist-lock connection, through the arm structure, into the fuselage primary frames.

Simulations include:

  • Symmetric and asymmetric lifting cases
  • Dynamic load factors
  • Ground alignment tolerances
  • Local stress concentration zones

The aim is to validate reinforcement strategies while keeping structural mass under control.

Safety & redundancy logic

Autonomous handling requires fault tolerance. Emergency winch redundancy is evaluated, partial arm failure scenarios are simulated, and a structured Failure Mode and Effects Analysis (FMEA) is performed.

Ground clearance studies are also conducted to confirm operational feasibility on realistic airfield surfaces.

Primary objective:

Demonstrate that the container lifting system can be integrated into the aircraft structure with credible load management, controlled risk, and aviation-level safety margins.

4. Landing Gear Integration

  • Structural integration of Q400-derived landing gear
  • Nacelle reinforcement studies
  • Retraction mechanism packaging validation
  • Ground stability assessment
  • Brake energy evaluation

Primary objective: Ensure compatibility between cargo bay geometry and gear integration.

5. Mass & Balance Consolidation

  • Updated mass breakdown
  • CG envelope refinement
  • Payload-range curve update
  • Structural margin validation

Primary objective: Confirm feasibility of ~30 t MTOW configuration.

Industrial Interface (TRL3)

TRL3 initiates structured dialogue with industrial stakeholders:

Potential discussions with:

  • Engine manufacturers
  • Landing gear suppliers
  • Aerospace structural partners
  • Embedded systems suppliers
  • Certification advisors

Objectives:

  • Validate technical assumptions
  • Identify certification pathways
  • Evaluate manufacturability constraints
  • Explore partnership opportunities

Risk Assessment at TRL3

Major technical risks evaluated:

  • Structural reinforcement of ventral opening
  • Cargo bay pressurization constraints
  • Robotic arm integration mass penalty
  • CG shift during container lift operations
  • Aeroelastic behavior of high-wing structure

Risk mitigation approach:

  • Analytical modeling
  • Redundancy concepts
  • Conservative structural margins
  • Iterative simulation

Environmental & Sustainability Considerations

TRL3 also integrates environmental refinement:

  • Updated fuel burn model
  • Structural weight reduction strategies
  • Sustainable Aviation Fuel (SAF) compatibility studies
  • Preliminary lifecycle thinking (LCA preparation)

Deliverables of TRL3

By the end of TRL3, the ISO-Plane program is expected to transition from a validated concept to a technically supported aircraft definition.

This stage does not produce a flying prototype yet — but it produces something equally important: engineering credibility.

The main deliverables include:

Structural validation package

  • Validated structural calculation reports (global and local load cases)
  • Finite Element Analysis (FEA) models and results
  • Reinforcement strategy definition for critical zones (cargo bay, wing box, landing gear integration)

Aerodynamic refinement

  • CFD simulation results
  • Updated drag breakdown
  • Refined performance and mission analysis
  • Updated payload–range assessment

Subsystem maturity documentation

  • Detailed cargo handling system architecture
  • Landing gear structural integration dossier
  • Systems interface documentation
  • Updated risk and mitigation analysis

Aircraft definition consolidation

  • Updated and coherent digital mock-up
  • Consolidated mass statement and CG envelope
  • Refined aircraft configuration freeze for next stage

Forward roadmap

  • Identified technical gaps toward TRL4
  • Demonstrator priorities
  • Preliminary industrial engagement framework
  • Structured TRL4 preparation roadmap

The objective of these deliverables is to demonstrate that the ISO-Plane architecture can withstand detailed engineering scrutiny, and that the project is ready to enter a demonstrator-oriented phase with reduced technical uncertainty.

Path Toward TRL4

TRL4 will focus on:

  • Subscale structural demonstrators
  • Ground testing of loading mechanism
  • Wind tunnel validation (if feasible)
  • Certification pre-discussions
  • Early industrial feasibility assessment

Strategic Vision

TRL3 transforms ISO-Plane from an architectural concept into an engineering program.

It is the stage where:

  • Feasibility becomes quantifiable
  • Industrial credibility begins
  • Technical maturity increases
  • Program risk is reduced

ISO-Plane TRL3 is the foundation for future prototype development.

ISO-Plane – Engineering the next generation of container air logistics.

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