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The Next Last Great Milestone

Gemini Sparkle

Key Takeaways:

  • Burt Rutan designed the *GlobalFlyer* for Steve Fossett's solo unrefueled global flight, prioritizing an unprecedented 82% fuel fraction, necessitating a highly efficient and lightweight structure.
  • The aircraft features an ultra-lightweight carbon fiber construction, including a 114-foot main spar weighing only 500 pounds, and a complex 13-tank automated fuel system within its unique twin-boom configuration.
  • Its development involved overcoming significant engineering challenges, such as adapting to a larger, less efficient engine (Williams FJ44) which required scaling up the entire aircraft, and meticulous paring down of all inessential structural components.
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In the reception area at Burt Rutan’s Mojave, California, skunk works, Scaled Composites, there sits on a corner table a small black tripod with a cup-shaped receptacle on top. Built by composites engineer Stan Stawski, who works at Scaled, it supported two tons before failing. It weighs less than four ounces.

Getting the most strength for the least weight is the real crux of aeronautical engineering. In airplanes, structure is a necessary evil. The same could be said of fuel, and the two evils come together in airplanes intended to fly extremely long distances.

FLYING Staff

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