SMART BLADE has considerable experience in designing custom-made sophisticated wind tunnel models. The Smart Blade engineering team has developed several wind tunnel test wings from different materials and for various testing purposes for internal use or for external customers. The wind tunnel test wings are directly machined from solid form-building material (e.g. OBOModulan^TM). The high precision machining is achieved using 3-axis and 5-axis CNC milling machines.

The inner structure is optimized during the design process in order to reduce weight without compromising the integrity of the wing. The internal blade structure is formed in a way that it is easy to attach custom sensors and actuators. Often additional metal beams and inner ribs are also attached to the blade structure to further increase stiffness and provide flexible mounting points for equipment. Many innovative ideas are incorporated in every test wind. That, in combination with the modular design principles allows maximum operational flexibility and longevity of the test wings .

Alternatively SMART BLADE also designs forms for conventional wind tunnel test wings which are laminated from glass-reinforced or carbon-reinforced laminates (GRP and CFRP). Naturally a combination of the two techniques is also possible and in this case the design complexity is only limited by the manufacturing capabilities of the external partner/customer responsible for the manual laminate laying process.