Laser-Cut Parts in The Impossible Airplane: What We’ve Learned

By Patrick Chamberlain, Aviation Director, RFI

In our journey to build The Impossible Airplane, a groundbreaking plane designed specifically for armless pilot Jessica Cox, we encountered some unexpected developments. During construction, we learned that Van’s Aircraft, the manufacturer of the kit we’re using, had produced certain parts using a laser-cutting process between 2022 and 2023. This has become a hot topic among builders and aviation enthusiasts because of concerns related to fatigue life and structural integrity.

As someone who’s deeply invested in both aviation and this specific aircraft, I wanted to share our take on Van’s recent findings on laser-cut parts and how it affects The Impossible Airplane. I’ll break this down in a way that everyone can understand, even though we’re delving into the engineering world for a bit.

What Are Laser-Cut Parts and Why the Concern?

Laser cutting is a precise method used to shape parts from sheet metal. While it’s a great technique for many applications, Van’s found that some laser-cut parts, particularly those with irregular holes or small cracks, may have a shorter lifespan due to metal fatigue.

Fatigue is a natural process that affects all metals—especially aluminum, which is widely used in aviation. Over time, repetitive stress can cause small cracks to form, and those cracks can grow if not detected and addressed.

After thorough testing, Van’s discovered that, under extreme conditions like aerobatics or flight training, some laser-cut parts might wear out faster than those made with traditional methods like CNC punching. However, this doesn’t mean these parts are unsafe. In fact, Van’s concluded that most laser-cut parts are still “acceptable for use” under normal flying conditions.

What Does This Mean for The Impossible Airplane?

So, how does this affect The Impossible Airplane? We’ve identified that the laser-cut parts in our plane include key areas like the tail, vertical stabilizer, flaps, ailerons, and portions of the fuselage. These parts are part of the aircraft’s internal structure and serve important roles in maintaining the plane’s overall integrity.

Van’s evaluation of these parts shows that while they may reduce the aircraft’s lifespan compared to traditionally punched parts, the difference is marginal under normal use. Since The Impossible Airplane is purpose-built for Jessica, who will not be flying it under extreme conditions like a flight school aircraft, this reduction in lifespan is even less of a concern.

Our engineers have reviewed Van’s findings and agree with their conclusions. This means that while we’re aware of the potential for slightly reduced life expectancy in these parts, it’s not something that impacts our safety or mission goals.

Critical Sections and Our Commitment to Safety

Van’s has taken steps to provide replacement parts for critical sections in all affected aircraft, including The Impossible Airplane. As of writing, our team is working to replace or reinforce these critical components following Van’s guidance, as an extra safety measure. While the likelihood of fatigue cracks is minimal, we’re committed to going the extra mile to ensure the long-term durability and safety of this special aircraft.

The Bigger Picture: Why We’re Moving Forward with Confidence

In our discussions with Van’s and our engineers, we’ve all come to the same conclusion: the risks associated with these laser-cut parts are manageable. Van’s has made it clear that even parts that are recommended for replacement do not pose an immediate risk to safety. The fatigue life of these parts is measured in thousands of hours, which is far beyond what we expect The Impossible Airplane to experience, especially given its specialized use.

Additionally, Van’s has offered solutions for builders who are concerned, including replacement parts and alternate solutions to mitigate any potential risks. We’re replacing the critical sections and reinforcing areas where needed, and we’ll be keeping a close eye on the aircraft during regular inspections.

Looking Ahead

Jessica and I are both incredibly excited to get The Impossible Airplane in the air. While the discovery of laser-cut parts might have been unexpected, it’s part of the learning curve when you’re building something revolutionary. The aircraft is still as strong, safe, and capable as ever.

We’ll remain mindful of the parts’ condition over time, and we’ll be performing regular inspections to ensure everything stays in top shape. This journey has been about pushing the limits—whether that’s in terms of technology, engineering, or personal achievement—and we’re thrilled to see how far it can take us.

In the end, this project isn’t just about an airplane. It’s about proving what’s possible, no matter the obstacles, and laser-cut parts or not, we’re going to fly.

The Impossible Airplane represents a major leap forward, not just for Jessica and me, but for everyone who believes in breaking barriers. We’re proud to continue sharing this journey with you, and we’re excited for the adventures to come.

For more information about RV laser cut parts, visit Van’s reference library on the topic: https://www.vansaircraft.com/faq/laser-cut-parts-reference-library/