Insert a Sine Wave shaped spar into a wing

[infoSC4MF]

I am trying to figure out how to insert a corrugated shaped spar into a plane wing section. It's easy to make a profile that is shaped like the spar and extrude it but it also needs to follow the wing shape that tapers as it moves outwardsAirfoil with spar shapeWing section 

[davebYYPCU]

Did you make the example wing with Loft or Sweep, do the same for the spar.

What will you do to make thickness, before or after the spar?

Might help....

[infoSC4MF]

The wing was made in on openVSP and then brought into fusion so I can't lose fat at the same time. I did try make two .5mm lines which were placed at either end of the wing segment but fusion refuses to loft them. Actually finding that Fusions loft tool seems to be a little buggy.

[infoSC4MF]

Here is the wing section with the two rough curves I tried to loft

[davebYYPCU]

Yep Fusion Loft tool is finicky, Fusion does not like your segmented wave curves either, and the profiles are not able to be selected, usually means it is imported geometry, not native fusion curves.  

If you fix that problem Fusion may get closer to cooperating for you....

Where the curves meet the skins you will need rails, 

because the wing panel is slightly concave you will need a rail at the top and bottom of the curve you want to Loft, 

The curves at the larger end go outside the skin, so that is not what you would want.

what is the end goal, cutting moulds with cnc, or 3d printing, my measurements predict the latter, print with infill, might work.

In the section view, you would have a rail similar to the underside of the skins, they would not be straight rails, in the front view.

There would be easier ways to add spars, straight ones, but you have a big job if you want to continue the wave spar, 

Few clues for you....

[etfrench · Accepted solution]

The attached file shows one way to create the wave.  I used two point circles with tangent lines between them.  If you use this method, you'll need to fine tune the circles to ensure they are inside the wing.

If you use the splines in your original file, then you should work on their form. The Curvature Comb is pretty wild (although it could just be a bug in the Curvature Comb )

[infoSC4MF]

Thanks, will give this a try 🙂

[infoSC4MF]

The wing we are building is a pretty wild wing concept 🙂 It will be a combination between SLS printed carbon infused nylon and machined EPO foam.